Part 1

Transmission

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material:

Assembly (Steps 1-32)

NOTE: Install new roll pins, retaining rings or bearings that were removed during disassembly.

Install bearings and bearing cups as a set.
1. Lubricate all components with transmission fluid during assembly.
2. Attach the clutch housing to the special tool.





3. NOTE: If a new rear output shaft bearing was installed or a new rear countershaft bearing is being used, install new bearing cups.

Install the rear countershaft bearing cup and the rear output shaft bearing cup.
^ Lubricate the bearing cups and the shift rail bearing with petroleum jelly.





4. Install the rear countershaft bearing.





5. Install the reverse idler gear bearing on the reverse idler gear shaft.





6. Install the reverse idler gear on the shaft.





7. Install the reverse idler gear into the case.





8. Install a new seal on the reverse idler bolt, then install the bolt in the transmission case.
^ Tighten to 27 Nm (20 ft. lbs).





9. NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new bearing cups.

Install the front input shaft bearing cup and the front countershaft bearing cup. Do not install the shims at this time.
^ Install the transmission main case.





10. Install the input shaft with the 3rd/4th synchronizer blocking ring.





11. Install the shift rails and shift forks on the mainshaft.





12. Install the mainshaft onto the clutch housing.
^ The notches on the shift rail should be pointing upward.
^ Align the shift rails in the bores.
^ The 3rd/4th shift fork has an oil deflector that will line up with an oil deflector on the inside of the case.
^ Make sure the 3rd/4th synchronizer blocking ring is aligned with the slots in the 3rd/4th synchronizer hub.





13. Using a jack and a block of wood, lift the mainshaft 13 mm (0.50 inch) upward, then tilt the countershaft inward and install the countershaft.
^ Make sure all synchronizer assemblies are in the neutral position.





14. Install the case while holding the countershaft bearing in place. Install 2 opposing bolts.
^ Tighten to 32 Nm (24 ft. lbs).

15. NOTE: Rotate the transmission so that the input shaft is pointing upward.

NOTE: Rotate the input shaft to seat the bearings.

Using the special tools, measure the input shaft end play by applying an upward load on the output shaft. Record the measurement.








16. Rotate the transmission so that the input shaft is pointing downward.





17. 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.





18. Remove the 2 bolts and lift the transmission main case off.





19. Using a jack and a block of wood, lift the mainshaft 13 mm (0.50 inch) upward, then tilt the countershaft outward and remove the countershaft.





20. While holding the mainshaft, release the jack and remove the mainshaft and shift assembly.





21. Remove the input shaft.





22. Remove the front input shaft bearing cup and the front countershaft bearing cup.





23. Using the special tools, install the new input shaft seal.





24. Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play.





25. Install the front input shaft bearing cup and the front countershaft bearing cup.





26. Install the input shaft and the 3rd/4th synchronizer blocking ring.





27. Install the mainshaft.
^ The notches on the shift rail should be pointing upward.
^ Align the shift rails in the bores.
^ The 3rd/4th shift fork has an oil deflector that will line up with an oil deflector on the inside of the case.
^ Make sure the 3rd/4th synchronizer blocking ring is aligned with the slots in the 3rd/4th synchronizer hub.





28. Using a jack and a block of wood, lift the mainshaft 13 mm (0.50 inch) upward, then tilt the countershaft inward and install the countershaft.





29. Clean the mating surfaces of the transmission main case and the clutch housing. Apply a bead of silicone rubber to the sealing surface on the clutch housing, then install the transmission main case.





30. Install the clutch housing-to-main case bolts.
^ Tighten the bolts in a star pattern to 32 Nm (24 ft. lbs).





31. Install the lock pins.





32. Install the lock plate and the lock plate bolts.
^ Tighten to 31 Nm (23 ft. lbs).