Warner T-4C 4 Speed

1. Coat countershaft gear thrust washers with suitable grease and install washers in case.

2. Position countershaft gear in case and install countershaft from rear of case, ensuring that thrust washers remain in place.

3. Position reverse idler gear in case with shift lever groove facing rear of case and install reverse idler shaft from rear of case, then install roll pin in shaft and center pin in shaft.

4. Install mainshaft assembly into case, being careful not to change position of synchronizer assemblies.

5. Install fourth gear blocking ring in third-fourth synchronizer sleeve, ensuring that synchronizer keys engage in notches in blocker ring, then install drive gear into case and engage with mainshaft.

6. Position mainshaft first gear against rear of case, then start new front bearing onto drive gear. Align bearing with bearing bore in case and drive bearing onto drive gear and into case using Tool J-25234, or equivalent, then install front bearing snap rings.

7. Apply a 1/8 inch bead of RTV sealant #732, or equivalent on case mating surface of front bearing cap and install bearing cap aligning marks made during disassembly. Apply non-hardening sealer on attaching bolts, install bolts, and torque to 15 ft. lbs.





8. Install first gear thrust washer with oil groove facing first gear on mainshaft, aligning slot in washer with first gear roll pin.

9. Position new rear bearing on mainshaft and align bearing with bearing bore in case, then drive bearing into case using Tool J-25234, or equivalent, and install rear bearing snap rings.

10. Install speedometer gear and retaining clip on mainshaft.

11. Apply non-hardening sealer to threads of reverse lever pivot bolt and start bolt into case. Engage reverse lever fork in reverse idler gear and reverse lever on pivot bolt, tighten bolt to 20 ft. lbs., and install retaining clip.

12. While rotating drive gear and mainshaft gears, check if blocker rings stick on gears. Rings can be released by carefully prying them off the cones.

13. Apply a 1/8 inch bead of RTV sealant #732, or equivalent, on cover mating surface of transmission, then place reverse lever in neutral and position cover on case.

14. Align cover to case by installing two dowel type bolts first, then install remaining cover bolts and torque to 10 ft. lbs.

NOTE: The offset lever to shift rail roll pin hole must be in a vertical position after cover installation.

15. Apply a 1/8 inch bead of RTV sealant #732, or equivalent on extension housing to transmission case mating surface, then place extension housing over mainshaft in a position where shift rail is in shift cover opening.

16. Install detent spring in offset lever and place ball in neutral guide plate detent position. Apply pressure on offset lever, slide offset lever onto shift rail and seat extension housing to transmission case.

17. Install extension housing retaining bolts and torque to 25 ft. lbs.

18. Align hole in offset lever and shift rail and install roll pin, then fill transmission to proper level with lubricant.