Shaft Assemblies and Housing Installation

Installation

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Install the 24 mm thrust shim on the transfer driven gear shaft, then install the shaft in the torque converter housing.
2. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing.
3. Install the countershaft 5th gear and reverse selector hub on the countershaft. If the reverse selector hub is a press-fitted type, refer to the installation.





4. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole. Then install the shift fork (B) and reverse selector (C) together on the shift fork shaft and countershaft (D). Secure the shift fork to the shift fork shaft with the lock bolt (E) and a new lock washer (F), then bend the lock washer against the bolt head.
5. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.





6. Place the thrust washer (A) in the transmission housing.





7. Place the reverse idler gear (A) in the transmission housing as shown, then slide it in the direction shown.





8. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (C) by turning the control shaft.
9. Install three dowel pins and a new gasket on the torque converter housing.





10. Place the transmission housing on the torque converter housing, then install the transmission housing mounting bolts along with the harness clamp bracket (A) and transmission hangers (B). Tighten the bolts in two or more steps.





11. Engage the reverse idler gear with the countershaft reverse gear and the mainshaft reverse gear. Then install the needle bearings (A), reverse idler gear shaft (B), and thrust washer (C) in the reverse idler gear, and install the reverse idler gear shaft holder (D) on the transmission housing.