Part 2

Transmission

Assembly (Steps 30-59)
30. Install the new 5th/6th shift fork snap ring.





31. Install the snap ring on the countershaft.





32. Install the 5th/6th gear synchronizer double cone and blocking ring as an assembly.





33. Install the spacer and the 5th drive gear needle bearing.





34. Install these components:
^ The 5th drive gear.
^ The 5th drive gear thrust washer.
^ A new 5th drive gear snap ring.
35. Using a suitable driver, install the reverse drive gear.
36. Install a new reverse drive gear snap ring.





37. Using the special tool, press the 5th driven gear.
^ Align the splines of the 5th driven gear with the drive gear on the countershaft extension.
38. Install the split ring and retainer.





39. Install the reverse shift fork, the reverse synchronizer and the strut retainer as an assembly.
^ The synchronizer hub has a tight fit on the shaft and may need to be installed separately.





40. Install the reverse shift fork snap ring.





41. Install a new reverse gear synchronizer snap ring.
42. Install the reverse gear synchronizer blocking rings.





43. Install the reverse gear needle bearing.





44. Install reverse gear.





45. Install the reverse gear thrust washer.





46. Install a new reverse gear snap ring.





47. Install the lower spacer, the rear output shaft roller bearing and the upper spacer.





48. Install the rear output shaft roller bearing snap ring.





49. Position the check ball on the shaft. Install the OSS sensor tone wheel. Install a new OSS sensor tone wheel retaining ring.
50. Install the reverse shift rail, then install a new reverse shift rail roll pin.
^ Install the pin until it is flush with the lever.
51. Install the bearing spacer and the race.





52. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface on the transmission case. Install the extension housing and tighten the bolts.
^ Tighten to 48 Nm (25 ft. lbs).
53. Install the vent hose.
54. Install the shift detent cover and the 4 shift detent cover bolts.
^ Tighten to 20 Nm (15 ft. lbs).





55. Install the output shaft flange.
56. Install the output shaft flange nut as follows:
^ Using the old flange nut, tighten to 135 Nm (100 ft. lbs).
^ Remove the nut and discard.
^ Install a new flange nut and tighten to 142 Nm (105 ft. lbs).





57. Apply thread sealer to the plug threads. Install the drain plug.
^ Tighten to 27 Nm (20 ft. lbs).





58. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
^ Tighten to 12 Nm (9 ft. lbs).





59. Install the clip and the line connector.