Adapter/Extension Housing and Front Bearing Retainer
DISASSEMBLY1. Drain transmission lubricant, if necessary.
2. Remove release bearing and lever.
Fig. 19:
3. Remove clutch housing bolts and remove housing.
4. Remove bolts holding shift tower to transmission case.
Fig. 17:
5. Remove shift tower from transmission case.
Fig. 18:
6. Remove shift tower gasket from shift tower or transmission case.
Fig. 20:
7. Remove reverse shift head detent ball plug.
Fig. 21:
Fig. 22:
8. Remove detent ball spring and ball with pencil magnet.
Fig. 23:
9. Remove shift arm retainer bolt.
Fig. 24:
10. Remove shift arm restrictor pins.
Fig. 25:
11. Remove shift lever shaft plug.
Fig. 26:
12. Remove shifter shaft with large magnet.
13. Remove the shift arm from the adapter housing.
Fig. 27:
14. Remove adaptertension housing bolts.
Fig. 28:
15. Loosen adaptertension housing by tapping it loose with plastic mallet.
Fig. 29:
16. Remove adaptertension housing.
17. Remove the bolts holding the front bearing retainer to the transmission case.
Fig. 30:
18. Remove the bearing retainer from transmission case.
Fig. 31:
19. Remove input shaft bearing snap-ring.
Fig. 32:
20. Remove cluster gear bearing snap-ring.
Fig. 33:
21. Separate intermediate plate and transfer case by tapping them loose with plastic mallet.
Fig. 34:
22. Separate the intermediate plate from the transmission case.
ASSEMBLY
1. Remove any residual sealer from transmission case, intermediate plate, adaptertension housing, and front bearing retainer.
Fig. 35:
2. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket TB1281, PIN 83504038, as shown, making sure to keep sealer bead to inside of bolt holes.
Fig. 36:
3. Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate. Verify that the transmission case is seated on the intermediate plate.
Fig. 37:
4. Install new front bearing snap rings.
5. Apply 1/8 inch wide bead of Threebond Liquid Gasket TB1281, P/N 83504038, to the front bearing retainer sealing surface.
Fig. 38:
6. Install the front bearing retainer and tighten bolts to 17 Nm (12 ft. lbs.).
7. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket TB1281, PIN 83504038, to sealing surface of adaptertension housing, making sure to keep sealer bead to inside of bolt holes.
Fig. 39:
8. Install adapter or extension housing on intermediate plate. Tighten housing bolts to 37 Nm (27 ft. lbs.) torque.
Fig. 40:
9. Position shift arm in shifter tower opening of adaptertension housing. Be sure that the shifter arm is
Fig. 41:
10. Start shifter arm shaft in hole in back of adaptertension housing. Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adaptertension housing.
11. Rotate the shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft.
Fig. 42:
12. Install the shift arm retainer bolt and tighten to 38 Nm (28 ft. lbs.).
Fig. 43:
13. Install and tighten shifter arm shaft plug to 18 Nm (13 ft. lbs.) torque.
Fig. 44:
14. Install shifter restrictor pins in shift tower and tighten to 27 Nm (20 ft. lbs.).
Fig. 45:
15. Install shift detent ball in detent opening.
Fig. 46:
16. Install detent spring.
Fig. 47:
17. Install detent plug and tighten to 19 Nm (14 ft. lbs.).
Fig. 48:
18. Install shift tower and new gasket on housing. Tighten tower bolts to 18 Nm (13 ft. lbs.) torque.
19. Install new metal O-ring to the backup lamp switch.
20. Install backup lamp switch. Tighten switch to 37 Nm (27 ft. lbs.) torque.
21. Install new seal in adaptertension housing.
22. Install clutch housing, release bearing, release fork and retainer clip.