Part 2
TransmissionAssembly (Steps 26-51)
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 large output shaft spacer.
31. Install a new check ball.
32. Install the small output shaft spacer.
33. Apply a 3.2 mm (1/8 inch) 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 0.05 mm (0.002 inch) 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. NOTE: Apply thread sealant to the drain plug threads.
Install the drain plug.
^ Tighten to 18 Nm (13 ft. lbs).
47. Install the output shaft speed (OSS) sensor.
^ Tighten to 10 Nm (89 inch lbs).
48. Install the output shaft oil seal.
49. Install the output shaft flange, washer and nut.
50. Install the clutch housing to the transmission.
^ Tighten to 31 Nm (23 ft. lbs).
51. Install a new clutch slave cylinder retaining clip.
52. Install the clutch release slave cylinder.
^ Tighten to 9 Nm (80 inch lbs).
