Output Shaft

Special Tool(s)

Puller, Bearing 205-D064 (D84L-1123-A) or equivalent

NOTE: Refer to the on-line Workshop Manual to view this illustration as an interactive exploded view, requires Adobe® Acrobat® 8.0 or higher.

NOTE: Refer to the on-line Workshop Manual to learn about using an Interactive Illustration.

Disassembly

NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.

NOTICE: Support the output shaft while using the press to prevent damage to the shaft or gears.

1. Remove the 5th/6th gear synchronizer assembly snap ring.

2. Using the Bearing Puller and a hydraulic press, remove the 5th/6th gear synchronizer assembly.
   • Inspect the 5th/6th gear synchronizer assembly and the 6th gear synchronizer ring and cone for wear or damage. Install new components as necessary.

3. Remove the 6th gear.
   • Inspect the 6th gear for wear or damage. Install a new gear as necessary.

4. Remove the 6th gear needle bearing.
   • Inspect the 6th gear needle bearing for wear or damage. Install a new needle bearing as necessary.

5. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.

Assembly

NOTICE: Lubricate all components with the recommended transmission fluid before reassembling.

1. Position the 5th/6th gear synchronizer assembly on the Bearing Puller and a hydraulic press.

2. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and synchronizer ring can occur.

   Install the 6th gear synchronizer ring and cone.
   • Align the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.

3. Install the 6th gear needle bearing.

4. Install the 6th gear.

5. Using the Bearing Puller and a hydraulic press, install the 5th/6th gear synchronizer assembly and the 6th gear.

6. Install the 5th/6th gear synchronizer assembly snap ring.