4)Remove second and third gears, needle cage and synchronizer ring for second gear. Don't mix synchro rings.

5)Remove first - second gear synchro assembly with shifting plates, springs and operating sleeve and disassemble.

6)Remove the synchro ring, first gear and pinion bearing retainer.

7)Remove the first gear shims.

8)Hold pinion assembly in soft jaw vise and remove the round nut using a pipe wrench or tap loose with a drift. On newer models the sleeve or shoulder is staked around the shaft and will have to be pryed up before the nut can be removed.

9)Remove the thrust washer and needle cage for first gear.

10)Press out the inner race of the needle bearing, the first gear thrust washer and pinion bearing,

WHAT TO LOOK FOR

1)Inspect all synchronizer components for signs of wear - when in doubt replace.

2)After cleaning the internal cone surface of the synchro rings with a wire brush, check the clearance between the synchro ring face and the synchro teeth of the corresponding gear. If it shows a wear of .024" or more it must be replaced. Replace if there is any doubt. Normal clearance should be 043". Remember, due to the tapered surface, the lower the reading the greater the wear.

3)Check for gear wear and damage. When replacing, the matching gear must also be replaced. First and second gear replacement also calls for front main drive shaft replacement.

4)Check the drive pinion for wear and damage. The pinion and ring gear must be replaced as a set if one or the other is bad.

5)Inspect the pinion bearing and needle bearings. Remember:
Replace any parts you have doubts about or your work will have been done for nothing!

ASSEMBLY

Before being pressed into postion, heat the following in a pan of oil over a hot plate or in an oven to approximately 190¥ - 200¥
the inner races of the pinion bearing
the needle bearing inner race for first gear

1)Slide a pinion bearing inner race onto the pinion shaft.

2)Slide on the pinion bearing and the next inner race, for first