Part 1
TransmissionSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Assembly (Steps 1-29)
1. Lubricate all components with transmission fluid during assembly.
2. Attach the transmission clutch housing to the special tool.
3. NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install the new bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at this time.
4. Install the input shaft.
5. Install the output shaft onto the input shaft.
6. Install the countershaft.
^ Lift the output shaft upward, tilt the countershaft and install.
7. Install the transmission case and tighten the bolts.
^ Tighten to 35 Nm (26 ft. lbs).
8. NOTE: Rotate the input shaft/output shaft to seat the bearings.
Using the special tools, measure the input shaft/output shaft end play by applying an upward load on the input shaft. Record the measurement.
^ Input/output shaft preload specification is 0.0127-0.0889 mm (0.0005-0.0035 inch).
9. Reposition the special tool on the countershaft.
10. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement.
^ Countershaft preload specification is 0.0127-0.0889 mm (0.0005-0.0035 inch).
11. Remove the transmission case.
12. Remove the countershaft.
13. Remove the output shaft.
14. Remove the input shaft.
15. Remove the input shaft bearing cup and the countershaft bearing cup.
16. Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play. Install the front input shaft bearing cup and the front countershaft bearing cup.
^ Lubricate the bearing cups with petroleum jelly.
17. Using the special tools, install the new input shaft seal.
18. Install the input shaft and 4th gear synchronizer blocking ring.
19. Assemble the shift rail assembly to the output shaft, then install the output shaft and shift rail as an assembly.
^ Rotate the output shaft to engage the 4th gear synchronizer blocking ring with the synchronizer keys.
20. Lift up the output shaft, then install the countershaft.
21. Install the 6th gear spacer and thrust washer.
22. Install the 5th/6th and reverse shift rail assembly and align the slots of the shift levers with the shift interlock plate.
23. Clean the mating surfaces of the transmission main case and the transmission clutch housing. Apply a bead of silicone rubber to the sealing surface on the transmission clutch housing. Install the transmission main case and the front offset lever.
^ Make sure the transmission is in NEUTRAL to keep the 3rd/4th gear shift rail from engaging. Check for correct alignment of roller with top shift rail.
^ Tighten the bolts in a star pattern to 35 Nm (26 ft. lbs).
24. Apply Threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
^ Tighten to 22 Nm (16 ft. lbs).
^ Pull up on the 5th/6th shift rail to align the slot of the interlock plate with the guide bolt hole.
25. Install a new front offset lever roll pin.
^ Install the pin until it is flush with the lever.
26. Apply Threadlock and sealer to the threads of the shift detent, then install the shift detent assembly.
^ Tighten to 40 Nm (30 ft. lbs).
27. Install the 5th/6th gear needle bearing.
28. Install 5th/6th gear, then install the 5th/6th gear synchronizer double cone and blocking ring as an assembly.
^ Before installing the blocking ring, index-mark the blocking ring to the synchronizer hub.
29. Install the 5th/6th gear shift fork and the 5th/6th gear synchronizer as an assembly.
^ The synchronizer hub has a tight fit on the shaft, and may need to be installed separately.
^ Make sure the synchronizer hub is correctly aligned with the blocking ring.