Geartrain Assembly In Fixture

Fig. 84:

1. Install Adapter 6747-1A on input shaft hub of fixture tool (Fig. 84). Then install Adapter 6747-2A on front bearing hub of countershaft. Adapter 6747-2A has a raised shoulder on one side. Be sure the shoulder is seated against the countershaft.

Fig. 85:

2. Install input shaft in fixture tool. Make sure Adapter Tool 6747-1A is positioned under shaft as shown (Fig. 85).
3. Install pilot bearing in input shaft (Fig. 85).

NOTE: The pilot bearing can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the output shaft and the small diameter side faces the input shaft.

Fig. 86:

4. Install fourth gear synchro, ring on input shaft (Fig. 86).

Fig. 87:

5. Adjust height of idler gear pedestal on assembly fixture (Fig. 87). Start with a basic height of 18.4 cm (7-1/4 inch). Final adjustment can be made after gear is positioned on pedestal.

Fig. 88:

6. Install assembled output shaft and geartrain in input shaft (Fig. 88). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
7. Install Adapter 6747-2A on front bearing hub of countershaft, if not previously done. The adapter has a shoulder on one side. The shoulder goes toward the countershaft.

Fig. 89:

8. Slide countershaft; (and adapter) into fixture slot. Verify that countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding (Fig. 89).
9. Check alignment of countershaft and output shaft gear teeth. Note that gears may not align perfectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 inch) will probably exist. This difference will not interfere with assembly. However, if the difference is greater than this, the countershaft adapter tool is probably upside down. Remove countershaft, reverse adapter tool, reinstall countershaft and check alignment again.

Fig. 90:

10. Position reverse idler in support cup of assembly fixture (Fig. 90). Be sure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary. Also be sure that short end of idler shaft is facing up as shown.

Fig. 91:

11. On 2-wheel drive transmission, thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 91).

Fig. 92:

12. Assemble 1-2 and fifth reverse-shift forks (Fig. 92). Arm of fifth-reverse fork goes through slot in 1-2 fork.

Fig. 93:

13. Install assembled shift forks in synchro sleeves (Fig. 93). Be sure forks are properly seated in sleeves.