Assembly

1. Install thrust ring lock ball in cluster gear journal. Use petroleum jelly to hold ball in place.





2. Install fifth gear thrust ring. Be sure thrust ring notch file over look hall





3. Assemble counter fifth gear, synchro sleeve, inserts and insert springs.





4. Lubricate two-piece bearing with petroleum jelly and install it in counter fifth gear.





5. Install counter fifth gear and synchro assembly on cluster gear journal.





6. Install synchro ring in synchro sleeve.





7. Install fifth spline gear on cluster journal. Tap spline gear into place with plastic mallet if necessary.





8. Install fifth gear selective snap ring. Use thickest snap ring that will fit in shaft groove.





9. Install reverse shift head and rail. Then install lock ball in shift head.





10. Position fifth gear shift fork in synchro sleeve.





11. Install fifth gear shift rail. Slide rail through fork, shift head, intermediate plate and reverse shift fork. Be sure interlock ball is not displaced during installation.





12. Align screw holes in shift fork and rail and install set screw. Tighten screw to 20 Nm (15 ft. lbs.) torque.





13. Install lock balls and springs in intermediate plate. Then install and tighten lock ball plugs to 19 Nm (14 ft. lbs.) torque





14. Install reverse shift arm bracket. Tighten bracket bolts to 18 Nm (13 ft. lbs.) torque.
15. Install reverse shift arm. Position arm on reverse fork pin and engage it with pin on shift arm bracket.
16. Verify that shift arm shoe is engaged in reverse idler gear. Then secure shift arm to pin on reverse fork with new E-clip.