Part 2
TransmissionAssembly (Steps 33-64)
33. Install the 3 detents and the 3 detent springs.
34. Install the 3 detent plugs.
^ Tighten to 28 Nm (21 ft. lbs).
35. Install the check ball.
^ Use petroleum jelly to hold the check ball in place.
36. NOTE: The thrust washer is positioned with the flat surface facing upward towards 5th gear.
Install the thrust washer and the 5th gear needle bearings.
37. Place the 5th gear synchronizer blocking ring and the synchronizer hub on the countershaft 5th gear. Install the synchronizer springs and inserts.
38. Install the sliding sleeve on the synchronizer hub.
^ Align the pockets in the blocking ring with the struts in the synchronizer.
^ The sliding sleeve is not reversible. Install the sleeve with the pointed teeth on the synchronizer sleeve away from 5th gear.
39. Install 5th gear synchronizer blocking ring.
40. Install the 5th gear synchronizer cone.
41. Install the 5th gear shift fork, the synchronizer assembly, the synchronizer cone and 5th gear as an assembly.
^ Lubricate the shift rail with transmission fluid. Using a plastic hammer, alternately tap the shift fork and the synchronizer cone into position.
42. Install a new split pin.
^ Install the pin until it is flush with the fork.
43. Install a new snap ring.
44. Install the 3rd/4th shift finger, then install a new split pin.
^ Install the split pin until it is flush with the shift finger.
45. Install new plastic spacers on the main shift rail.
46. Install the main shift rail, then install the 1st/2nd shift finger. Install new split pins.
^ Install the split pins until it is flush with the shift finger and the shift rail.
47. Install the OSS sensor tone wheel check ball.
^ Use petroleum jelly to hold the check ball in place.
48. Place the OSS sensor tone wheel on the output shaft, aligning the slot in the OSS wheel with the check ball. Using the special tool, install the OSS sensor tone wheel.
^ The OSS sensor tone wheel is brittle. Gently tap the tone wheel into position.
49. Install a new OSS sensor tone wheel retaining ring.
50. Install the 5th/reverse gear lockout spring, arm, seal and top bolt.
^ Tighten to 20 Nm (15 ft. lbs).
51. Install the 5th/reverse gear lockout side bolt.
^ Tighten to 20 Nm (15 ft. lbs).
52. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface of the transmission case.
53. Install a new split pin in the gear shift offset lever.
^ The split pin should be flush in the gear shift offset lever.
54. Seat the extension housing and install the bolts.
^ Tighten to 32 Nm (24 ft. lbs).
^ Fill the gear shift offset lever with petroleum jelly.
55. Position a new extension housing seal onto the extension housing. Using the special tool, install the extension housing seal.
^ Lubricate the seal with transmission fluid.
56. Install the output shaft speed (OSS) sensor.
^ Tighten to 10 Nm (89 inch lbs).
57. Position the output flange onto the output shaft. Install the output flange nut and tighten until the output flange is fully seated onto the output shaft.
58. Remove the nut.
59. Install the output flange oil seal, the output flange washer and the output flange nut.
^ Tighten to 142 Nm (105 ft. lbs).
60. Install a new plastic retainer.
61. Install the clutch slave cylinder.
62. Install the clutch slave cylinder connector and engage the clip.
63. Fill the transmission with transmission fluid to the specified level.
^ Transmission capacity is 3.0 liters (6.3 pints).
64. Apply Threadlock and sealer to the fill plug threads and install the fill plug.
^ Tighten to 25 Nm (18 ft. lbs).