Assembly

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. Assembly.




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. Removal.




11. Apply a 1.5 to 2mm. 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.).