Overhaul (Assembly)
ASSEMBLYTransmission
Special Tool(s):
Material:
1. NOTE: Soak the blocking rings in transmission fluid for 10 minutes.
Lubricate all components with transmission fluid during assembly.
2. Position the countershaft cluster gear in the case.
3. CAUTION: Failure to correctly support the case during bearing installation will result in permanent distortion of the case.
Using the special tools and a press, install the rear countershaft bearing assembly.
1 Position 2 6.35-mm (0.25-inches) pieces of bar stock between the countershaft and the case.
2 Press the rear countershaft bearing assembly in the case.
4. Install the rear countershaft bearing cup.
5. NOTE: Do not install the shims at this time.
Install the countershaft rear bearing retainer.
^ Tighten to 21 Nm (15 ft. lbs.).
6. Using the special tool, measure the countershaft cluster gear end play.
^ If the end play is not within specification, remove the countershaft rear bearing retainer and install the necessary thickness shim(s). Reinstall the countershaft rear bearing retainer and recheck the end play.
^ Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play adjustment is complete.
7. Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft and the reverse gear overtravel stop.
8. Install a new pin.
9. Align the reverse gearshift lever, the reverse shift fork and the reverse positioning spring.
10. NOTE: Observe the reverse positioning spring rotation. The spring must rotate counterclockwise into its installed position.
Install the reverse shift fork.
^ Place the reverse idler gear and bushing into the NEUTRAL position. Align the reverse shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing.
11. Install the output shaft assembly.
12. Apply pipe sealant to the shift lever reverse pin threads. Position the looped end of the reverse positioning spring around the shift lever reverse pin. Install the pin.
13. Install the roller bearings, the input shaft bearing spacer, the thrust bearing and the thrust washer.
^ Coat the 15 bearings, the spacer, the thrust bearing and the thrust washer with grease.
14. Install the 4th gear synchronizer blocking ring.
^ Align the notches in the synchronizer blocking ring and the synchronizer hub inserts.
15. NOTE: Verify that the 4th speed synchronizer blocking ring is still in position.
Align the flat on the 4th gear clutching teeth with the countershaft cluster gear, then install the input shaft.
16. NOTE: Do not install the end play shims at this time.
NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
Install the bearing race in the bearing retainer.
17. Install the input shaft bearing retainer with the notch facing upward.
18. Install the 4 input shaft bearing retainer bolts.
^ Tighten to 21 Nm (15 ft. lbs.).
19. Install the output shaft rear bearing cup.
20. Install the reverse gear shift rail.
^ Align the ball stud with the slot in the case and align the reverse gear shift rail with the reverse shift fork. Once the ball stud enters the case, rotate the reverse gear shift rail until the ball aligns with the reverse gearshift lever. Rotate the reverse gear shift rail counterclockwise until the ball stud fully engages the reverse gearshift lever.
21. Install the 5th speed cluster gear, the synchronizer blocking ring, the synchronizer assembly and the 5th gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing, the alignment tab on the reverse brake ring must engage the alignment slot in the extension housing.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer and the 5th speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip.
25. CAUTION: Do not under any circumstance apply silicone sealant to the top of the transmission case. The sealant could fall into the transmission and affect transmission operation.
Apply a 3.2-mm (1/8-inches) bead of silicone rubber to the sealing surface on the case cover.
26. NOTE: Verify that all of the synchronizers are in the NEUTRAL position and the gear shifter forks in the cover are in the NEUTRAL position.
Install the case cover.
^ Position the cover toward the filler plug side of the transmission and lower it until the gear shifter forks engage the synchronizers. Continue to lower the cover and move it into position to engage the reverse gearshift lever.
27. Install the 10 case cover bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
28. Install a new output shaft bearing and a new snap ring.
29. Using the special tool, install a new output shaft seal.
30. Install the small output shaft spacer.
31. Install a new check ball.
32. Install the large output shaft spacer.
33. Apply a 3.2-mm (1/8-inches) bead of silicone rubber to the sealing surface on the extension housing.
34. Install the detent ball, the shifter detent spring and the gearshift offset lever.
1 Coat the shifter detent spring with petroleum jelly and install it in the gearshift offset lever.
2 Lubricate the detent plate and install the detent ball in the NEUTRAL position on the plate.
3 Position the gearshift offset lever in the extension housing with the gear shift interlock spring over the detent ball.
35. CAUTION: To prevent component damage, the alignment tab on the reverse brake ring must align with the alignment slot in the extension housing.
NOTE: Verify that the oil pick-up funnel engages the 5th gear synchronizer.
Slide the gearshift offset lever and the extension housing into place as an assembly. Press downward on the gearshift offset lever to compress the shifter interlock spring and push the gearshift offset lever and extension housing into place.
36. Install the identification tag and the 7 extension housing bolts.
^ Tighten to 54 Nm (40 ft. lbs.).
37. Install a new roll pin and the gearshift shaft bushing.
38. Install the spring, the shift lever and the gearshift shaft.
39. Install a new gearshift lever offset lever roll pin.
40. Using the special tools, measure the output shaft end play.
1 Place the transmission in a vertical position.
2 Install the special tool.
3 Push upward on the input shaft and record the dial indicator reading.
41. CAUTION: Install the thickest shim closest to the front bearing cup to provide support for the cup.
CAUTION: Although zero end play is the ideal, end play up to rum (0.002 inches) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.
NOTE: Select a shim with a thickness equal to the dial indicator reading. This will provide zero end play.
Rotate the transmission to the horizontal position and remove the input shaft bearing retainer. Remove the bearing race and install the necessary shim(s).
42. CAUTION: Do not cover the notch in the input shaft bearing retainer with sealer.
Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the input shaft bearing retainer.
43. Install the input shaft bearing retainer and the 4 bolts.
^ Tighten to 21 Nm (15 ft. lbs.).
44. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
45. Install the shift cover plate and the 4 shift cover plate bolts.
^ Tighten to 19 Nm (14 ft. lbs.).
46. Install the drain plug.
^ Tighten to 18 Nm (13 ft. lbs.).
47. Install the clutch housing to the transmission.
^ Tighten to 31 Nm (23 ft. lbs.).
48. Install a new clutch slave cylinder retaining clip.
49. Install the clutch release slave cylinder.
^ Tighten to 9 Nm (7 ft. lbs.).
