Geartrain Housing

GEARTRAIN HOUSING

DISASSEMBLY





1. Remove the transmission.
2. Remove the clutch release bearing/slave cylinder.
3. Remove the sealing ring (6) from countershaft bore (4) using a screwdriver.
4. Remove the input shaft seal (1) using a screw driver.
5. Remove the countershaft bolt (5).
6. Remove the input shaft snap ring (2).





7. Remove the output shaft collared nut (5) and the output flange (6).
8. Drive out the roll pin (8) with a suitable roll pin punch and remove the shift actuator (7).
9. Remove the reverse gear detent plug (1).
10. Remove the rear section retaining bolts (4).
11. Separate the rear section from the front section.





NOTE: The countershaft, input shaft, and shift unit can only be removed as an assembly from the rear section.

12. Remove the four bolts(1) attaching the shifter plate (2) to the rear section.
13. Use an arbor press to press the shafts and shift unit out of the rear section of the transmission.





14. Mount the mainshaft and countershaft together (1) in a vise with protective jaws. Remove the shifter (2).
15. Disassemble the rear section housing.

ASSEMBLY

NOTE: Special Tool ASSEMBLY AID 9204 can be used to hold the main and counter shafts together while assembling the geartrain housing.

1. Assemble the rear section housing.





NOTE: Be certain that the shift forks are aligned in the shifting sleeves on the shafts.

2. Fit the shifter assembly (2) on to the main and counter shafts (1).





3. Fit the rear section of the transmission (4) over the main shaft and shift shaft. Align the reverse gear (1) to the gear sets as shown.





4. Use the output flange (3) and the collared nut (1) to draw in the output shaft. Remove the nut and flange when the rear section is in place.





5. Install the four bolts (1) that attach the shifter plate (2) to the rear section. Tighten the bolts to 28 Nm (21 ft. lbs.).
6. Install the counter shaft bolt (5). Tighten the bolt to 90 Nm (66 ft. lbs.).
7. Install the snap ring (2) on the input shaft.
8. Use Special Tool 9123 Drift to drive in a new input shaft seal.
9. Install a new sealing ring (6) in the counter shaft bolt opening (4).
10. Install the clutch release bearing/slave cylinder.








11. Apply a 1.5 to 2 mm bead of Loctite 5203 sealer or equivalent to the front section as shown.





12. Fit the front and rear transmission sections together.
13. Install the bolts (4) and tighten to 28 Nm (21 ft. lbs.).
14. Install the shift actuator (7) and drive the roll pin (8) in until flush.
15. Drive the reverse gear detent (1) in until fully seated.
16. Install the oil filler plug (2). Tighten the plug to 50 Nm (37 ft. lbs.).
17. Install the oil drain plug (3). Tighten the plug to 60 Nm (44 ft. lbs.).
18. Install the output flange (6) and collared nut (5). Tighten the nut to 180 Nm (133 ft. lbs.).