Tools Required

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



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



3. Install the 3rd speed gear (7) to the mainshaft.
4. Install the spacer (6) to the mainshaft.
5. Install the thrust washer (5) to the mainshaft.
6. Install the 3rd speed gear inner cone (4) to the mainshaft.
7. Install the 3rd speed gear friction cone (3) to the mainshaft.
8. Install the 3rd speed gear blocking ring (2) to the mainshaft.
9. Install the 3rd/4th speed gear synchronizer assembly (1) to the mainshaft (the groove on the sleeve faces the 3rd speed gear).
10. Start the press operation.
11. Stop pressing before the keys engage the blocking ring slots.
12. Lift and rotate the 3rd speed gear in order to engage the keys with the blocking ring.
13. Continue pressing until the synchronizer is seated.



14. Install the 4th gear blocking ring (2) to the mainshaft (1).
15. Install the 4th gear friction cone (3) to the mainshaft (1).
16. Install the 4th gear inner cone (4) to the mainshaft (1).
17. Install the 4th gear thrust washer (5) to the mainshaft (1).
18. Install the 3rd/4th synchronizer circlip (6) to the mainshaft (1).



19. Install a NEW small tapered bearing (1) to the mainshaft, using the J 39473  (2), V-blocks, and a hydraulic press.



20. Install the 2nd speed gear caged needle bearing (2) to the mainshaft (1).
21. Install the 2nd speed gear spacer (3) to the mainshaft (1).



22. Install the 2nd speed gear (2) to the mainshaft (1).
23. Install the 2nd speed gear inner cone (3) to the mainshaft (1).
24. Install the 2nd speed gear friction cone (4) to the mainshaft (1).
25. Install the 2nd speed gear blocking ring (5) to the mainshaft (1).
26. Install the 1st/2nd synchronizer assembly (6) to the mainshaft (1) (The ID groove on the sleeve faces the 1st speed gear.)



27. Start the press operation.
28. Stop pressing before the keys engage the blocking ring slots.
29. Lift and rotate the 2nd speed gear in order to engage the keys with the blocking ring.
30. Continue pressing until the synchronizer is seated.



31. Install the 1st speed gear blocking ring (6) to the mainshaft (1).
32. Install the friction cone (5) to the mainshaft (1).
33. Install the inner cone (4) to the mainshaft (1).
34. Install the the split washers (3) to the mainshaft (1).
35. Install the the split washer retainer (2) to the mainshaft (1).



36. Install the 1st speed gear bearing spacer (2) to the mainshaft (1).
37. Install the 1st speed gear caged needle bearing (3) to the mainshaft (1).
38. Install the 1st speed gear (4) to the mainshaft (1).
39. Install the large tapered bearing (5) to the mainshaft (1).

Tools Required

1. Install a NEW bearing race (1) on the input shaft (3), using the J 28537-17  (2) and a hydraulic press.



2. Install a NEW tapered bearing (1) on the input shaft (3). Use the J 25234  (2) and a hydraulic press.