9. Transmission Assemble
^ Tools Required^ J 36850 Transjel(R) Transmission Assembly Lubricant
1. Install the input shaft (3) with the input shaft needle bearing (2) onto the main shaft (1).
2. Install the main shaft (3) and the input shaft assembly (1) into the lower case (2).
3. Move all of the gearshift shafts to their neutral position.
4. Inspect the main shaft and the countershaft components for smooth engagement and rotation. If the main shaft and countershaft fail to rotate smoothly, remove the main shaft from the lower case and inspect the countershaft for binding.
5. Apply Loctite(TM) 599 RTV silicone sealer or equivalent to the upper case mating surface (3).
Notice: Refer to Fastener Notice in Service Precautions.
6. Connect the upper case (1) to the lower case (2). Secure the cases with the ten bolts.
^ Tighten the upper-to-lower case retaining bolts to 23 Nm (17 ft. lbs.).
7. Connect the input shaft bearing retainer (1) to the upper and lower case. Secure the input shaft bearing retainer with the eight bolts (2,3).
^ Tighten the input shaft bearing retainer bolts to 23 Nm (17 ft. lbs.).
8. Apply Loctite(TM) 599 RTV sealer or equivalent to the rear case mating surface (3).
9. Install the rear case (1) to the rear of the upper and lower case. Secure the rear case with the twelve bolts.
^ Tighten the rear case bolts to 23 Nm (17 ft. lbs.).
10. Apply Loctite(TM) 599 RTV silicone sealer or equivalent to the gearshift lever case mating surface.
11. Install the transfer case to the rear case using a bolt.
^ Tighten the bolt to 28 Nm (21 ft. lbs.).
12. Connect the gearshift lever case to the rear cases. Secure the gearshift lever case with the ten bolts.
^ Tighten the gearshift lever case bolts to 17 Nm (113 ft. lbs.).
13. Connect the clutch housing to the upper and lower case. Secure the clutch housing with eight bolts (1,2).
^ Tighten the clutch housing bolts to 45 Nm (33 ft. lbs.).
14. Connect the clutch release bearing (2) and the clutch fork boot (1) to the input shaft.