Assembly

Transmission









Transmission Case and Shift Components - Disassembled View














Transmission Gear Assemblies - Disassembled View













1. Lubricate all components with transmission fluid during assembly.

2. Attach the transmission clutch housing to the Transmission Holding Fixture.





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 main case-to-clutch housing bolts.
- Tighten to 48 Nm (35 lb-ft).





8. NOTE: Rotate the input shaft/output shaft to seat the bearings.

Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the input shaft/output shaft end play by applying an upward load on the input shaft. Record the measurement.





9. Reposition the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge on the countershaft.

10. NOTE: Rotate the countershaft to seat the bearings.

Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement.





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. Input shaft, output shaft and countershaft endplay specification is 0.0127-0.0889 mm (0.0005-0.0035 in). Install the front input shaft bearing cup and the front countershaft bearing cup.
- Lubricate the bearing cups with petroleum jelly.









17. Using the Input Shaft Oil Seal Installer with Handle, 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 48 Nm (35 lb-ft).









24. Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
- Tighten to 27 Nm (20 lb-ft).

- 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 lb-ft).





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.

30. Install the new 5th/6th shift fork snap ring.





31. Install a new 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 the following 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 a suitable 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 a new 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 the 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 a new rear output shaft roller bearing snap ring.





49. Position the check ball on the shaft. Install the Output Shaft Speed (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 (35 lb-ft).

53. Install the vent hose.

54. Install the shift detent cover and the 4 shift detent cover bolts.
- Tighten to 20 Nm (177 lb-in).





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 lb-ft).

- Remove the nut and discard.

- Install a new flange nut and tighten to 142 Nm (105 lb-ft).





57. Apply threadlock and sealer to the drain plug threads. Install the drain plug.
- Tighten to 27 Nm (20 lb-ft).





58. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
- Tighten to 12 Nm (106 lb-in).





59. Install the clutch hydraulic tube and clip to the connector.