Assemble

Counter Gear
1. Coat bore at each end of counter gear with grease.

Countergear, Disassembled:

2. Hold appropriate dummy shaft in gear and install 25 needle bearings and a retainer washer in each end of gear.
3. Install counter gear, thrust washers and countershaft in case.

Checking Countergear End-play:

4. Place transmission case in vertical position and check end play with a feeler gauge. If end play exceeds 0.018 inch, replace thrust washers as required to obtain 0.004-0.018 inch end play.
5. Once end play has been established, remove countershaft with dummy shaft.
6. Allow counter gear assembly to remain in case.

Reverse Idler Gear
1. Install idler gear, thrust washers and shaft in case.

Reverse Idler Gear, Disassembled:

2. Make sure that thrust washer with flat side is at the web end, and that the spur gear is toward the rear of case.
3. Check reverse idler gear end play in same manner and to the same clearance as the counter gear. If end play is within limits of 0.004-0.018 inch, leave gear in case.

Low-Reverse Synchronizer

Low-Reverse Synchronizer, Disassembled:

1. Install an insert spring in the groove of the low-reverse synchronizer hub. Make sure that the spring covers all of the insert grooves.
2. Start hub in sleeve, making sure that alignment marks are properly indexed.
3. Position three inserts in hub, making sure that small end is over spring and that shoulder is on inside of hub.
4. Slide sleeve and reverse gear onto hub until detent is engaged.
5. Install other insert spring in front of hub to hold inserts against hub.

Second-Third Synchronizer

Second-third Synchronizer, Disassembled:

1. Install one insert spring into the synchronizer hub groove, making sure that all three insert slots are fully covered.
2. With alignment marks on hub and sleeve aligned, start hub into sleeve.
3. Place three inserts on top of retaining spring and push assembly together.
4. Install remaining insert spring so that spring ends cover same slots as do other spring. Do not stagger springs.
5. Place a synchronizer blocking ring in each end of sleeve.

Main Drive Line
1. Lubricate mainshaft splines and machined surfaces with transmission lube.

Mainshaft Components:

2. Slide low-reverse synchronizer onto mainshaft with teeth end of gear facing toward rear of shaft. Secure in place with snap ring.
3. Coat tapered machined surface of low gear with grease. Place blocking ring on greased surface.
4. Slide low gear onto mainshaft with blocking ring toward rear of shaft. Rotate gear as necessary to engage the three notches in blocking ring with synchronizer inserts. Secure low gear with thrust washer and snap ring.
5. Coat tapered machined surface of 2nd gear with grease and slide blocking ring onto it. Slide 2nd gear with blocking ring and 2-3 synchronizer onto mainshaft. Tapered machined surface of 2nd gear must be toward front of shaft. Make sure that notches in blocking ring engage synchronizer inserts. Secure synchronizer with snap ring.

Shift Lever & Related Components:

6. Install new 0-ring on each of two shift lever shafts. Lubricate shafts with transmission lube and install them in case. Secure each lever on its shaft with a flat washer, lock washer and nut.

Main Drive Gear, Disassembled:

7. Coat bore of main drive gear shaft with thick coat of grease. Install 15 needle bearings in gear pocket.
8. Position drive gear assembly into case.

Shift Rods & Forks, Disassembled:

9. Place a detent spring and plug in case. Place 2-3 shift fork in synchronizer groove. Rotate fork into position and install 2-3 shift rail. It will be necessary to depress detent plug to enter rail in bore. Move rail inward until detent plug engages center (neutral) notch. Secure fork to shaft with set screw.
10. Install interlock plug in case. If 2-3 shift rail is in neutral position, top of interlock will be slightly lower than surface of low-reverse shift rail bore.
11. Place low-reverse shift fork in groove of synchronizer. Rotate fork into position and install low-reverse shift rail. Move rail inward until center (neutral) notch is aligned with detent bore. Secure fork to shaft with set screw.
12. Install remaining detent plug and spring. Secure spring with slotted head set screw. Turn set screw in until head is flush with case.
13. Install new expansion plug in case.
14. Install drive gear through front of case with bearing in place on shaft.
15. Position new front bearing retainer gasket on case. Place bearing retainer on case, making sure oil return groove is at the bottom. Install and tighten attaching screws to 30-36 ft lbs.
16. Install large snap ring on mainshaft rear bearing. Place bearing on mainshaft with snap ring end toward rear of shaft. Press bearing into place and secure with snap ring.
17. Hold speedometer drive gear lock ball in detent and slide gear into place. Secure gear with snap ring.

Final Assembly
1. Place transmission in vertical position. Working through drain hole in bottom of case, align bore of counter gear and thrust washers with bore of case, using a screwdriver.
2. Working through rear of case, push dummy shaft out with countershaft. Before countershaft is completely inserted, make sure the hole that accommodates roll pin is aligned with hole in case.

Removing Countershaft Roll Pin:

3. Working through lubricant filler hole, install roll pin in case and countershaft.
4. Install filler and drain plugs, making sure magnetic plug is installed in bottom of case.
5. Install extension housing with new gasket and torque attaching cap screws to 42-50 ft lbs.
6. Place transmission in gear, pour lubricant over entire gear train while rotating input and output shafts.
7. Install cover with new gasket and torque attaching screws to 20-25 ft lbs. Coat gasket and cover screws with sealer.