Tools Required

J 22873 Main Shaft Bushing Installer

Important: Lightly oil all bearing and synchronizer surfaces with the recommended lubricant before assembly.

1. Lightly oil the mainshaft bearing surfaces and the bearings for the mainshaft gears with SAE 90 Multipurpose Oil.
2. Install the 3rd gear bearing on the mainshaft.
3. Install the 3rd gear.



4. Position the 3rd/4th gear synchronizer assembly on the mainshaft.
5. Turn the mainshaft 180 degrees and using a hydraulic press start pressing on the 3rd/4th synchronizer assembly.



6. Align the following components while pressing on the synchronizer hub:

•	The center synchronizer ring tabs with the holes in the third gear

•	The cam on the blocker ring with the slot in the synchronizer hub

•	The inside tab on the blocker ring with the slots in the inner ring




7. Install the 4th gear. Ensure the synchronizer center ring tabs are aligned in the gear.
8. Install the 4th gear bearings.



9. Install the 4th gear roller bearing spacer using the J 22873  (1) and a hydraulic press. Do not damage the 4th gear bearings while pressing the roller bearing spacer.



10. Install the retaining ring for the 4th gear bearing roller spacer.



11. Install the 5th gear bearing.
12. Install the 5th gear.



13. Install the 5th/6th synchronizer assemble on the mainshaft. The double ridge on the synchronizer sleeve faces the 6th gear.
14. Using a hydraulic press and the J 22873  (1) install the 5th/6th synchronizer assembly.



15. Install a NEW retaining ring for the 5th/6th synchronizer hub.



16. Install the 2nd gear bearing.
17. Install the 2nd gear.



18. Install the following 2nd gear synchronizer rings:

18.1.

The inner ring

18.2.

The center ring aligning the tabs with the holes in the gear

18.3.

The blocker ring aligning the inside tabs with the inner ring




19. Position the 1st/2nd synchronizer hub on the mainshaft. The retaining ring groove faces toward 1st gear.



20. Using a hydraulic press install the 1st/2nd synchronizer hub.
21. Align the following components while pressing on the synchronizer hub:

•	The center synchronizer ring tabs with the holes in the third gear

•	The cam on the blocker ring with the slot in the synchronizer hub

•	The inside tab on the blocker ring with the slots in the inner ring




22. Install the retaining ring for the 1st/2nd gear synchronizer hub.



23. Install the 1st/2nd synchronizer sleeve on the synchronizer hub.

•	Align the thick shoulder of the sleeve facing the first gear.

•	Align the sleeve stops with the flat area of the hub.




24. Install the synchronizer blocks, the springs, and the shift block plungers.
25. Install the retaining ring in the 1st/2nd synchronizer hub.
26. Move the synchronizer sleeve in the neutral position in order to hold the shift block plungers in place.



27. Install the 1st gear bearing.
28. Install the 1st gear.



29. Install the reverse gear hub.

•	The oil grooves on the hub go towards reverse gear.

•	Use a brass drift and a hammer to install the hub.

30. Install the reverse gear shift sleeve. The oil holes in the sleeve go towards reverse gear.



31. Install the reverse gear bearing race.
32. Install the reverse gear bearing.
33. Install the reverse gear.
34. Install the 6th gear synchronizer ring on the front end of the mainshaft.