Special Tools

Mainshaft

1. Install the 3rd speed gear caged needle bearing.
2. Install the spacer.



3. Check the 3rd/4th speed gear synchronizer assembly scribe marks for correct positions.



4. Install the 3rd/4th synchronizer assembly as follows:

4.1.	Start the press operation.

4.2.	STOP pressing before the keys engage the blocking ring slots.

4.3.	Lift and rotate the 3rd speed gear in order to engage the keys with the blocking ring.

4.4.	Continue pressing until the synchronizer is seated.

5. Install the following parts in order, using the J 36183 , the J 36184 , and a hydraulic press:

5.1.	The 3rd speed gear

5.2.	The 3rd speed gear inner cone

5.3.	The 3rd speed gear friction cone

5.4.	The 3rd speed gear blocking ring

5.5.	The 3rd/4th speed gear synchronizer assembly (the groove on the sleeve faces the 3rd speed gear).




6. Install the 3rd/4th synchronizer retainer ring.



7. Install a new mainshaft small tapered bearing, using the J 39473 and a rubber mallet.



8. Install the 2nd speed gear caged needle bearing and bearing spacer.



9. Do the following when installing the 1st/2nd synchronizer assembly:

9.1.	Start the press operation.

9.2.	Stop pressing before the keys engage the blocking ring slots.

9.3.	Lift and rotate the 2nd speed gear in order to engage the keys with the blocking ring.

9.4.	Continue pressing until the synchronizer is seated.

10. Install the following parts in order using the J 39371 and a hydraulic press:

10.1.

The 2nd speed gear

10.2.

The 2nd speed gear inner cone

10.3.

The 2nd speed gear friction cone

10.4.

The 2nd speed gear blocking ring

10.5.

The 1st/2nd synchronizer assembly (The ID groove on the sleeve faces the 1st speed gear.)




11. Install the following parts in order:

11.1.

The two piece thrust washer

11.2.

The blocking ring

11.3.

The friction cone

11.4.

The inner cone




12. Install the following parts in order:

12.1.

The 1st speed gear locking ring

12.2.

The 1st speed gear caged needle bearing

12.3.

The 1st speed gear

13. Using J 39441 and J-39441-20 , install the mainshaft large tapered bearing.



14. Using J 39441  (1) and J-39441-20  (2), install the 6th speed gear.

Input Shaft

1. Install a new bearing race on the input shaft, using the J 28537-17 and a hydraulic press.



2. Install a new tapered bearing on the input shaft. Use the J 25234 and a hydraulic press.