Disassembly/Assembly

DISASSEMBLY

Fig. 1 Exploded view of transmission (Part 1 of 2):

Fig. 1 Exploded view of transmission (Part 2 of 2):

Disassemble transmission in numbered sequence shown noting the following:
1. Pull extension housing (15) toward rear while pushing change shifter toward left side.
2. Remove countershaft locknut as follows:
a. Use front edge of blade or chisel to loosen baffle on countershaft locknuts.
b. Shift OD-R synchronizer sleeve to reverse side, then shift 1st-2nd speed synchronizer sleeve to 2nd speed side.
c. Remove countershaft locknut.
3. Remove counter overdrive gear (32) and ball bearing using a suitable puller tool.
4. Remove reverse idler gear shaft as follows:
a. Remove four reverse idler gear shaft mounting bolts.
b. Drive reverse idler gear shaft from inside of case.

Fig. 2 Main shaft rear bearing removal:

5. Remove main shaft center bearing as follows:
a. Remove main shaft bearing snap ring.
b. Remove main shaft rear bearing with puller tools No. MD998020 and MD998028 or equivalents.

Fig. 3 Countershaft bearing removal:

6. Remove countershaft center bearing and front bearings using removal tool No. MD998192 or equivalent.
7. Pull countergear upwards in case and remove main drive gear assembly with bearing toward front of case.

ASSEMBLY

Assemble in reverse numeric order shown noting the following:
1. Install counter front bearing using installation tool No. MD998199 or equivalent.
2. Apply transmission oil to lip of oil seal, then drive oil seal into front bearing retainer using seal installation tool No. MD998200 or equivalent.

Fig. 12 Bearing retainer clearance measurement:

3. Prior to installing front bearing retainer, (62), select a spacer which will bring clearance "C" within 0-0.004 inch.
4. Apply sealant to both sides of front bearing retainer gasket and connect to case, then immediately set spacer selected in above step in place and install bearing retainer.
5. Drive in counter rear bearing with installation tool No. MD998199 or equivalent.
6. After installing snap ring on main shaft bearing, drive main shaft bearing into transmission case using installation tool No. MD998067 or equivalent.

Fig. 13 Synchronizer hub key positions:

7. Assemble synchronizer hub as follows:
a. Assemble synchronizer hub and sleeve. Ensure hub and sleeve slide smoothly.
b. Insert three keys into groove of hub. Assemble hub and keys as shown in.
c. Install two synchronizer springs. Ensure steps of front and rear springs are positioned on synchronizer key, but not on same key.

Fig. 14 Synchronizer ring clearance measurement:

8. Engage synchronizer ring OD gear as shown before installing OD gear to ensure dimension "A" is less than 0.020 inch. If more than specified, replace ring and/or gear.

Fig. 15 Overdrive gear & shift rail installation:

9. Install over drive gear and 1st-2nd shift rail as shown in.
10. Install counter rear bearing using installation tool No. MD998199 or equivalent.
11. Drive in OD-R shift fork spring pin using a suitable pin punch.

Fig. 16 Split pin installation location:

12. Drive in spring pin so slit is centered in line with shift rail, as shown in. Install spring pin for 3-4 and 1-2 shift forks in same manner.

Fig. 17 Steel ball, poppet springs & plugs installation:

13. Install steel balls, poppet springs and plugs as follows:
a. Insert steel ball and spring into each shift rail.
b. Insert poppet spring with small end on ball side. Three springs are identical.
c. Following installation, seal plug head with sealant.

Fig. 18 Extension housing installation:

14. Install extension housing while pushing on change shifter in direction of arrow in. Fit control finger into groove in selector.

Fig. 19 Neutral return plunger installation:

15. Install neutral return plungers A and B and springs, then install steel ball and resistance spring and tighten seal plugs.

Fig. 20 Speedometer sleeve position:

16. Install speedometer assembly, match mating marks to number of teeth on speedometer driven gear and install speedometer assembly.