Special Tools

For equivalent regional tools, refer to Special Tools

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

5.1.	The 3rd speed gear (3)

5.2.	The spacer (4)

5.3.	The thrust washer (5)

5.4.	The 3rd speed gear inner cone (6)

5.5.	The 3rd speed gear friction cone (7)

5.6.	The 3rd speed gear blocking ring (8)

5.7.	The 3rd/4th speed gear synchronizer assembly (9). The groove on the sleeve faces the 3rd speed gear.




6. Install the 3rd/4th synchronizer retainer ring (1).



7. Install a new mainshaft small tapered bearing (2), using the J 39473 installers  (1), V-blocks, and a hydraulic press.



8. Install the 2nd speed gear caged needle bearing (2) and bearing spacer (1).



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 1st/2nd installer 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 1st speed gear two piece washer (5)

11.2.

The 1st speed gear locking ring (4)

11.3.

The 1st speed gear synchronizer blocking ring (3)

11.4.

The 1st speed gear outer cone (2)

11.5.

The 1st speed gear inner cone (1)




12. Install the following parts in order:

12.1.

The 1st speed gear caged needle bearing (1)

12.2.

The 1st speed gear (2)

12.3.

The mainshaft inner seal O-ring (3)




13. Using J 39441 installer  (1), J 39441-20 adapter  (2), and a press, install the mainshaft large tapered bearing (3).



14. Using the J 39441 gear installer  (1) and the J 39441-10 adapter  (2), install the 6th speed driven gear (3).

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



2. Install a new tapered bearing on the input shaft. Use the J 44735 tube and a hydraulic press.