D 350 Pickup V8-360 5.9L VIN 5 (1992)
3.
Lubricate and install 5h gear bearings on countershaft.
4.
Coat bearing spacer with petroleum jelly, then install bearing spacer on countershaft.
Fig. 77 Installing synchronizer sleeve
5.
Install synchronizer sleeve on hub of countershaft 5th gear. Tapered side of sleeve faces front and flat side faces rear.
Fig. 78 Shift fork installation
6.
Install shift fork in synchronizer sleeve as shown.
Fig. 79 Countershaft 5th gear assembly installation
7.
Install assembled 5th gear, synchronizer sleeve and shift fork. Align fork with shift lug rail, then gear with bearings and countershaft. Start
components onto shaft and rail, then tap gear and fork into place with plastic mallet.
8.
Align roll pin holes in shift fork with notches in shift lug rail, then install roll pins from top side of fork. Note that roll pins are a one way fit,
due to small shoulder at one end of each pin.
Fig. 80 Installing 5th gear synchronizer strut & spring assemblies
9.
Install synchronizer struts and springs in 5th gear hub. Install struts in hub slots first, then install springs by compressing them with screwdriver
and working springs into hub and struts.
