Part 1

ASSEMBLY

WARNING: Use welding gloves or tongs when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: A bearing heater is used to assembly some components. Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100° - 149° Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

INPUT SHAFT





1. Heat input shaft bearing (1) on bearing heater (2) to a maximum of 149 Celsius (300° Fahrenheit).





2. Using welding gloves or tongs, install bearing (2) on input shaft (1).





3. Push input shaft mainshaft bearing seal (1) on the end of fifth gear (2).

COUNTERSHAFT





1. Install first/reverse gear bearing oil slinger on the rear housing end of the countershaft.
2. Heat rear housing countershaft bearing (1) on bearing heater (2) to a maximum of 149 Celsius (300° Fahrenheit).





3. Using welding gloves or tongs, install countershaft bearing (1) on countershaft (2).





4. Heat front housing countershaft bearing (1) on bearing heater (2) to a maximum of 149 Celsius (300° Fahrenheit).





5. Using welding gloves or tongs, install front housing countershaft bearing (1) on countershaft (2).

MAINSHAFT





1. Position mainshaft in Fixture 9605 mounted in vise.
2. Install second gear bearing (1) on mainshaft (2).





3. Install second gear (1) on mainshaft (2).





4. Install second gear stop ring (1) with teeth pointing up on second gear (2).





5. Install second gear inner friction ring (1) on stop ring (2).





6. Install second gear outer friction ring (1) on stop ring (2).





7. Install second gear blocker ring (1) on stop ring (2).





8. Install 1-2 synchronizer hub (1) on mainshaft and synchronizer rings (2).





9. Install 1-2 synchronizer hub (1) and hub snap ring (2).





10. Install 1-2 synchronizer sleeve (3) on the hub (2) and push sleeve to the bottom of the hub.

NOTE: 1-2 synchronizer sleeve (3) and hub (2) have one small tooth. They must be aligned to install synchronizer sleeve (3) on hub (2).

11. Install 1-2 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind synchronizer sleeve (3).





12. Install first gear blocker ring (1) on synchronizer hub (2).





13. Install first gear outer friction ring (1) on synchronizer hub (2).





14. Install first gear inner friction ring (1) on synchronizer hub (2).





15. Install first gear stop ring (1) with teeth pointing down on synchronizer rings and hub (2).
16. Hold first gear stop ring (1) on synchronizer rings (2) and center 1-2 synchronizer sleeve on the hub.





17. Install first gear (1) and bearing (2).





18. Heat thrust washer (1) and reverse gear bearing race (2) on bearing heater to a maximum of 149 Celsius (300° Fahrenheit).





19. Using welding gloves or tongs, install thrust washer (2) and reverse gear bearing race (1) on mainshaft.





20. Install reverse gear (1) and bearing (2).





21. Install reverse gear inner friction ring (1) on reverse gear (2).





22. Install reverse gear outer friction ring (1) on inner blocker ring (2).





23. Install reverse gear blocker ring (1) on friction ring (2).





24. Install reverse gear synchronizer hub (1) with snap ring (2) on the top on mainshaft.





25. Heat mainshaft bearing (1) on bearing heater (2) to a maximum of 149 Celsius (300° Fahrenheit).





26. Using welding gloves or tongs, install mainshaft (1) bearing (2) on mainshaft.
27. On 4x4 transmission install mainshaft (1) bearing (2) snap ring.





28. Install reverse synchronizer hub (1) detents (2).





29. Install reverse gear (2) synchronizer sleeve (1) on hub and center sleeve on hub.





30. Turn mainshaft and Fixture 9605 over and secure in vise.
31. Install third gear bearing (1) on mainshaft (2).





32. Install third gear (1) on mainshaft (2).





33. Install third gear stop ring (1) with teeth pointing up on third gear (2).





34. Install third gear inner friction ring (1) on stop ring (2).





35. Install third gear outer friction ring (1) on stop ring (2).





36. Install third gear blocker ring (1) on stop ring (2).





37. Install 3-4 synchronizer hub (1) on third gear synchronizer rings (2).





38. Install third gear synchronizer hub (1) snap ring (2).





39. Install 3-4 synchronizer sleeve (3) on hub (2) and push sleeve to the bottom of the hub.

NOTE: 3-4 synchronizer sleeve (3) and hub (2) have one small tooth. They must be aligned to install synchronizer sleeve (3).

40. Install 3-4 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents (1) behind synchronizer sleeve (3).





41. Install fourth gear blocker ring (1) on synchronizer hub (2).





42. Install fourth gear outer friction ring (1) on synchronizer hub (2).





43. Install fourth gear inner friction ring (1) on synchronizer hub (2).





44. Install fourth gear stop ring (1) with teeth pointing down on synchronizer hub (2).
45. Hold fourth gear stop ring (1) on synchronizer hub (2) and center 3-4 synchronizer sleeve on hub.





46. Install fourth gear (1) and bearing (2).





47. Heat fourth gear thrust washer (1) on bearing heater (2) to a maximum of 149 Celsius (300° Fahrenheit).





48. Using welding gloves or tongs, install fourth gear (1) thrust washer (2).





49. Install fourth gear (1) snap ring (2).





50. Install sixth gear (1) and bearing (2) on mainshaft (3).





51. Install sixth gear stop ring (1) on sixth gear (2).





52. Install sixth gear friction ring (1) on stop ring (2).





53. Install 5-6 synchronizer hub (1) on sixth gear synchronizer rings (2).





54. Heat mainshaft bearing (1) on bearing heater to a maximum of 149 Celsius (300° Fahrenheit).





55. Using welding gloves or tongs, install mainshaft bearing (1) on mainshaft.
56. Install mainshaft bearing (1) snap ring (2).





57. Install 5-6 synchronizer sleeve (1) on hub (2) and push sleeve to the bottom of the hub.





58. Install 5-6 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind synchronizer sleeve (3).





59. Install fifth gear friction ring (1) onto hub (2).





60. Install fifth gear blocker ring with teeth pointing down (1) onto hub (2).
61. Hold fifth gear blocker ring (1) onto hub (2) and center 5-6 synchronizer sleeve on hub (2).