Page 1977 of 2438
When assembling intermediate shaft, make
sure all speed gears turn freely.
1-2 SYNCHRONIZER (DUAL-CONE)
Fig. 6 Install 3-4 Synchronizer Hub and 3rd Speed Gear
Fig. 1 2nd Speed Gear
Fig. 2 1-2 Synchronizer Hub Snap Ring
Fig. 3 Install Intermediate Shaft Rear Bearing
Fig. 4 3-4 Synchronizer Hub Snap Ring
Fig. 5 Remove 3-4 Synchronizer Hub and 3rd Speed Gear
Ä TRANSAXLE 21 - 17
Page 1978 of 2438
Fig. 3 1st Speed Gear and 1-2 Synchronizer AssemblyFig. 4 Split Thrust Washer
Fig. 5 Intermediate Shaft Assembly
21 - 18 TRANSAXLE Ä
Page 1979 of 2438
SYNCHRONIZERS
Fig. 1 1-2 and 3-4 Synchronizer Sleeves and Hubs
Fig. 2 5th Speed Synchronizer
Ä TRANSAXLE 21 - 19
Page 1980 of 2438
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly, or with previous model years tran-
saxles; they will NOT function correctly.
Fig. 3 Synchronizer Identification
Fig. 4 Synchronizers
21 - 20 TRANSAXLE Ä
Page 1981 of 2438
GEARSHIFT HOUSING
Roll pin must be flush with top of lever.
Fig. 1 Gearshift Housing Disassembled
Fig. 2 Remove or Install Roll Pin and LeverFig. 3 Dust Boot
Ä TRANSAXLE 21 - 21
Page 1982 of 2438
The C-Clip groves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always use a new oil seal when
selector shaft is removed. Proper torque to the 5-R blocker attaching
bolts is very important (Fig. 8).
Fig. 4 Remove Oil Seal
Fig. 5 Install Oil Seal
Fig. 6 Remove Vent Cap
Fig. 7 Crossover Shaft Roll Pin
Fig. 8 5-R Blocker Attaching Bolts
Fig. 9 5-R Blocker Assembly
21 - 22 TRANSAXLE Ä
Page 1983 of 2438
For Disassembly: Drive roll pin out far enough
to clear the selector shaft, but not through. The
pin must remain in the selector so not to break
the housing.
Fig. 10 Crossover Shaft
Fig. 11 Selector Shaft C-Clip
Fig. 12 Selector Shaft C-Clip
Fig. 13 Selector Assembly Roll Pin
Fig. 14 Remove or Install Selector Shaft
Fig. 15 Disassembled View
Ä TRANSAXLE 21 - 23
Page 1984 of 2438
DIFFERENTIAL BEARING RETAINER
Fig. 1 Remove Differential Bearing Retainer Seal
Fig. 2 Install Differential Bearing Retainer Seal
Fig. 3 Remove Differential Bearing Retainer Cup
Fig. 4 Differential Bearing Retainer
Fig. 5 Install Oil Baffle
Fig. 6 Insert (Select) Shim and Differential Bearing Retainer Cup
21 - 24 TRANSAXLE Ä