Assembly

Installing Countershaft Assembly:

1. Insert countershaft in transmission case through top opening.

Installing Input Shaft Assembly:

2. Insert input shaft in transmission case through top opening.

Removing Output Shaft:

3. Insert output shaft in transmission case. Mate input and output shaft assemblies by positioning them at an upward angle and setting them together.

Installing Center Bearing Race:

4. Install output shaft center bearing outer race, using a suitable drift Seat center bearing outer races, maintaining bearing position shown.
5. Install countershaft center bearing. Ensure center bearing outer races are squarely positioned in bores.
6. Install center bearing cover onto transmission case with reference arrow pointing upward. Insert center bearing cover retaining bolts, then torque to 14-19 ft lbs (19-25 Nm). Ensure all center bearing cover retaining bolt heads are marked with and "8."
7. Position transmission with input shaft and clutch housing facing upward, then install front cover oil seal, using tool No. T77J-7025-G or equivalent. Ensure input shaft front bearing outer race is squarely positioned in bore.

Measuring Dimensions A, B, C & D:

8. Manually install countershaft front bearing. If any related components have been replaced, measure dimensions A, B, C and D, then if necessary select a suitable bearing shim that will bring endplay to within limits. Dimensions are as follows:

Installing Selected Shim:

a. Dimension A, Height of input shaft bearing outer race above transmission front bearing cover mating surface.
b. Dimension B, Depth of front cover outer race bore (input shaft).
c. Dimension C, Depth of countershaft front bearing race (transmission case to front cover mating surface).
d. Dimension D, Depth of front cover outer race bore (countershaft).
9. Shim computation equations are as follows:
a. Dimension B - (Dimension A + shim thickness) = 0.002-0.006 inch (0.05-0.015 mm).
b. Dimension C + (Dimension D - shim thickness) = 0.006-0.010 (0.015-0.25 mm).

Shaft Installation Selective Shim Chart:

c. If necessary to adjust endplay, select a suitable shim from chart.
10. Remove any sealant residue remaining on mating surfaces of transmission and front cover. To prevent damage to oil seal lip during assembly, tape the input shaft splines along their length.

Countershaft Front Bearing Bore Selective Spacer Chart:

11. Apply a thin coat of oil to front cover (install shim with groove showing). Select a suitable spacer from chart, then assemble spacer to transmission case countershaft front bearing bore.

NOTE: If necessary, apply a suitable grease to spacer, bearing cover and oil baffle to retain them during assembly.

12. Apply a 1/8 inch bead of silicone rubber 6AZ-19562-B or equivalent to front cover and front cover retaining bolt threads.
13. Assemble front bearing cover to transmission case, then insert attaching bolts and torque to 9-12 ft lbs (12-16 Nm). Ensure front bearing cover retaining bolt heads are marked with a "6."
14. Position transmission horizontally in a suitable holding fixture, then install Woodruff key and 5th gear sleeve, using a suitable tool.

Exploded View Of Output And Countershaft Components:

15. Install 5th gear needle bearing onto countershaft 5th gear.

Installing 5th Gear:

16. To install 5th gear assembly, perform process in two steps, first install gear installing spacer T88F-7025-F, then when tool bottoms, add gear installing spacer T88T-7025-G and press 5th gear assembly the rest of the way into position.
17. Place counter lever assembly in transmission, then install thrust washer and retaining ring.
18. Apply a suitable sealant to counter lever retaining bolts, then insert and torque to 6-7 ft lbs (8-9 Nm).
19. If removed, install 5th/reverse in top cover, then insert 5th/reverse shift rail through top cover bore and 5th reverse shift fork.

Installing Spring & 5th Gear:

20. Insert spring and detent ball into lower part of shift rod.

Assembling 5th/Reverse Synchronizer:

21. Assemble 5th/reverse synchronizer hub, sleeve and 5th gear synchronizer ring to 5th/reverse shift fork and rod assembly. Install longer flange toward front of transmission. Reference mark on synchronizer sleeve must be installed toward reverse side of gear.
22. Assemble 5th/reverse shift fork and shift rail assembly to countershaft, then mate shift fork gate to 5th/reverse counter lever end.
23. Install 5th/reverse shift fork and shift rail assembly with threaded attaching bolt bores aligned. To facilitate assembly, position 5th/reverse shift fork into last of three detent positions. Return shift fork to neutral gear position after installation.

Installing Counter Lever Assembly:

24. Apply a suitable sealant to 5th/reverse shift rail attaching bolts, then insert 5th/reverse shift rail attaching bolt into transmission case. Torque bolt to 16-22 ft lbs (21-29 Nm).
25. Apply a suitable sealant to oil passage retaining bolt, then insert oil passage retaining bolt and torque to 6-8 ft lbs (8-10 Nm).
26. Assemble split washer and thrust washer onto countershaft.

Reverse Idler Gear Endplay Selective Split Washer Chart:

27. If clutch hub and/or counter reverse gear have been replaced, select new split washers from chart, that will bring end play to 0.0039-0.0078 inch. Ensure split washers are a matched set of identical thickness.
28. Install reverse synchronizer ring and needle bearings into counter reverse gear, then assemble counter reverse gear and needle bearings onto countershaft as an assembly.
29. Install thrust washer onto countershaft.
30. Manually press thrust washer forward against shoulder on countershaft, then while maintaining forward pressure, insert feeler gauge between thrust washer and counter reverse gear and measure endplay.

Counter Reverse Gear Selective Thrust Washer Chart:

31. Counter reverse gear endplay should be 0.007-0.011 inch. If endplay is not as specified, select a suitable thrust washer from the chart that will bring endplay to within specifications.
32. Temporarily install a suitable spacer in place of countershaft bearing, then loosely install countershaft locknut to retain component. Installation of a suitable spacer prevent and split washers from slipping off shaft and avoids interference with reverse idler gears.
33. Install reverse idler gear assembly, then apply a suitable sealant to attaching bolt.
34. Insert reverse idler attaching bolt, then torque to 58-86 ft lbs (78-116 Nm).
35. Drive sleeve and reverse gear assembly onto output shaft using a suitable tool, ensuring longer flange of reverse gear is facing rearward.
36. Install output shaft rear bearing, using suitable tool.
37. Remove temporary spacer from countershaft.
38. Manually install countershaft rear bearing. Torquing shaft locknuts without fully seating bearing can cause damage to output shaft threads.
39. Lock transmission in 1st and 3rd gears, then install and finger tighten new output and countershaft locknuts.
40. Torque output shaft locknut to 160-200 ft lbs (216-270 Nm), then torque the countershaft locknut to 94-144 ft lbs (127-194 Nm). Ensure to use new locknuts as locknuts unstaked at disassembly cannot be reused.
41. stake locknuts to bottom shaft groove, using suitable tool, then install speedometer drive gear and steel ball into output shaft.
42. Install speedometer drive gear to output shaft retaining ring. Speedometer driver contains three detents into which steel drive ball can be installed into either detent. Depending on application, one of two different speedometer drive gears may be installed. Replace gear with same color as was removed.
43. Remove any sealant residue from mating surfaces of transmission case and extension housing, then apply a 1/8 inch bead of a suitable sealant to transmission case. Extension housing bushing cannot be serviced. If bushing requires service, extension housing must be replaced as a unit.
44. Position extension housing on transmission case, then insert attaching bolts. Torque bolts to 24-34 ft lbs (32-46 Nm).
45. Place synchronizers in neutral, then ensure that shift forks on top cover assembly are in neutral.
46. Place top cover on transmission case, then engage shift forks with synchronizers.
47. Apply a suitable sealant to the two rearmost to cover retaining bolts, then insert and finger tighten bolts. Insert remaining top cover retaining bolts, less sealant, then torque all bolts to 12-16 ft lbs (16-21 Nm). Do not apply a sealant to top cover or transmission case mating surfaces.
48. Install transmission drain plug, then torque to 29-43 ft lbs (39-58 Nm).
49. If removed, install rear extension housing oil seal, using a suitable tool. Ensure oil seal drain hole is facing downward.
50. Fill transmission with specified quantity of fluid.