Measure the clearance between the third and second gears.
Measure the clearance between fourth gear and the bearing cone.
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) bearing (fourth gear end).
CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
Remove fourth gear and the synchronizer blocking ring.
Remove the snap ring.
CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
NOTE: Inspect all the synchronizer components for wear and damage; refer to Synchronizers.
Use an (A) arbor press, (B) Shaft Protector, and (C) Pinion Bearing Cone Remover to press off the (D) synchronizer hub assembly, (E) synchronizer blocking ring, and (F) third gear.
Use an arbor press, (A) Shaft Protector, and (B) Bearing Pulling Attachment to press off the (C) bearing (third gear end).
Use Dial Indicator/Magnetic Base to measure input shaft gear runout.
Inspect the input shaft for worn or damaged gears.
NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference. Inspect the synchronizer blocking rings.
Measure the clearance from the side of the gear.
Inspect for smooth engagement with the gear.
Inspect for worn or damaged teeth or tapper surface.
Inspect the synchronizer hub.
Inspect for worn or damaged splines, synchronizer insert groove or end surface.
Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the third/fourth synchronizer hub and its shift fork.
Assembly
NOTE: Whenever a bearing has been removed, it must be replaced with a new one.
Use an arbor press, Shaft Protector, (A) Bearing Cone Replacer, and (B) Axle Bearing/Seal Plate to press on the (C) bearing (third gear side).
Install the third gear.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.
NOTE: Be sure to have the ridge facing the third gear when installing the synchronizer hub assembly.
NOTE: Ensure that the four oil grooves in the synchronizer hub are facing the third gear.
Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer and (C) Axle Bearing/Seal Plate to press on the (D) synchronizer blocking ring and (E) synchronizer hub assembly.
Install the snap ring.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.
Use an arbor press, (A) Shaft Protector, (B) Bearing Cone Replacer, and (C) Axle Bearing/Seal Plate to press on the (D) synchronizer blocking ring, (E) fourth gear, and the (F) bearing.
NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.
