Part 1

Transmission

Special Tool(s):

Material:

Assembly (Steps 1-25)

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 two 6.35 mm (0.25 inch) pieces of bar stock between the countershaft and the case.
2. Press the rear countershaft bearing assembly in the case.





4. 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.





5. Install the rear countershaft bearing cup.





6. NOTE: Do not install the shims at this time.

Install the countershaft rear bearing retainer.
^ Tighten to 21 Nm (15 ft. lbs).





7. 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.





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 5th gear and 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 gear shifter fork, the synchronizer blocking ring, the synchronizer assembly and the 5th gear shifter fork pin 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 inch) bead of silicone rubber to the sealing surface on the case cover.