Assembly

1. Install mainshaft assembly into case.
2. Install 1-2 and 3-4 shift forks into their synchronizer sleeves. The roll pin bosses on the forks must face each other.
3. Install countershaft into the case.

NOTE: It may be necessary to move the mainshaft to one side in order for the countershaft to be easily inserted.

4. Install correct size selective snap ring in front of the input shaft bearing. Select the thickest snap ring that will fit in the groove.
5. Install small caged needle bearing inside input gear. Install synchronizer ring on to input shaft Check clearance between ring and gear. If clearance is less than 0.009 inch, replace ring and/or input shaft.
6. Install synchronizer ring and input shaft into case. Rotate input shaft so flats on shaft face countershaft.

NOTE: It may be necessary to gently tap the input shaft into position.

7. Install a new snap ring on to outer bearing race. The longer portion of the race must be installed in the case.
8. Slide outer ball bearing on to mainshaft. Using a suitable tool, press bearing into position on mainshaft. When pressed into position, all gears and shafts must rotate freely.
9. If removed, drive a new seal into input shaft front bearing retainer.
10. Install large snap ring retaining input shaft bearing to the case.
11. Check input shaft front bearing retainer to bearing clearance as follows:
a. With retainer selective shim removed, use a suitable depth micrometer to measure the distance between the top machined surface to the spacer surface. Record the reading.
b. Bottom the input shaft bearing so the snap ring is flush against the case.
c. Using a depth micrometer, measure distance from the top of the outer front bearing race to the machined surface of the case.
d. Subtract the distance of the bearing to case from the retainer dimensions. This will give the required maximum selective shim size to obtain a 0.000-0.004 inch clearance.
e. Measure, then install the appropriate size selective shim in the front bearing retainer.
12. Install countershaft front outer bearing race and non-selective spacer. Install the countershaft rear outer bearing race.
13. Install a new gasket between the front bearing retainer and case. Position the retainer on to the case (with selective shim installed). Install the four bolts and four studs. Torque to 22-30 ft lbs (29-40 Nm).
14. Check and adjust countershaft end-play as follows:
a. Place transmission so rear of mainshaft and countershaft face upward. Install countershaft rear selective spacer.
b. Force the countershaft downward so it bottoms against the front bearing retainer.
c. Place a straight edge across the rear countershaft selective spacer in the case.
d. Try to turn the spacer. If the spacer turns lightly, replace the spacer with the next larger size. Install a spacer so the clearance between the spacer and straight edge is 0.000-0.002 inch.
15. Install rear bearing retainer into case. Torque Allen head bolts to 11-16 ft lbs (14-21 Nm).

NOTE: Ensure spacer installed does not fall out of position when installing the rear bearing retainer.

16. Position reverse idler gear shaft assembly on to case. Install the Allen head bolts. Install reverse idler gear shaft remover tool, T85T-7140-A on to the shaft and drive assembly into position. Torque Allen head bolts to 11-16 ft lbs (14-21 Nm).
17. Install two caged needle bearings, reverse idler gear and thrust washer on to idler shaft. The boss on the idler gear should face away from the transmission. Install locknut and torque to 15-42 ft lbs (20-56 Nm). If required, turn nut to the next hole and install cotter pin.
18. Install spacers and counter-reverse gear on to mainshaft.
19. Using a suitable tool, press reverse gear sleeve on to mainshaft.
20. Install caged needle bearing and reverse gear on to mainshaft.
21. Assemble overdrive synchronizer hub and sleeve as follows:
a. Install hub into sleeve. The recessed boss on the sleeve must face the front of the transmission. The large boss on the hub must face the front of the transmission.
b. When installing hub into the sleeve and three keys, ensure that the single tooth between the two spacers will touch the key. Install springs so open ends do not face each other.
22. Install overdrive synchronizer on to mainshaft. The recessed boss of the sleeve must face the front of the transmission.
23. Press sleeve of overdrive gear on to mainshaft.
24. Install ring on overdrive synchronizer.
25. Slide small spacer, caged needle bearing and overdrive gear on to mainshaft. Check clearance between overdrive gear and synchronizer ring. If clearance is less than 0.009 inch, replace ring and/or overdrive gear.
26. Install counter-overdrive gear and ball bearing on to countershaft along with the 1-2 shift rail. Seat bearing into position. Ensure the rail engages the forks.
27. Install lock ball and spacer on to mainshaft.
28. Place rear bearing over mainshaft and press bearing into position.
29. Install new locknuts on to countershaft and mainshaft assemblies. Double engage transmission into two gears, then torque mainshaft locknut to 180-195 ft lbs (243-263 Nm). Torque countershaft locknut to 115-137 ft lbs (155-185 Nm). Disengage transmission.
30. Stake locknuts on mainshaft and countershaft.
31. Install and interlock plunger into bore between 1-2 and 3-4 shift rails. Position 1-2 shift rail so that flats for the poppet ball, spring and interlock plunger are in correct position. Ensure roll pin holes for the shift forks are aligned properly.
32. Install overdrive-reverse shift fork on to synchronizer sleeve. Slide 3-4 shift rail through the overdrive-reverse shift fork into the case and into the 3-4 shift fork inside the case. Position the shift rail flats to accept the poppet balls and interlock plunger. Insert the interlock plunger into the bore between the 3-4 shift rail and overdrive-reverse shift rail. Ensure roll pin holes in the fork are aligned.
33. Insert the overdrive-reverse shift rail so it engages the forks in the case. Ensure roll pin holes in the fork are aligned.
34. Insert poppet ball and spring into 1-2 (upper) bore in case. The small end of the spring should be installed toward the ball. Install the set screw and tighten until screw head is 0.24 inch below the top of the bore.
35. Insert a poppet spring and poppet ball into 3-4 and overdrive-reverse bore (side two bores in the case). The small end of the spring faces toward the ball. Install and tighten the bolts.
36. Install roll pins into shift forks. If removed, install switch actuator and roll pin.
37. Install shift gates on to appropriate shift rails. Move the 1-2 gate to the rear of the rail.
38. Position a new gasket between the transmission case and transfer case adapter. Ensure selector arm is out of the gates and the change shifter is at the rear of the adapter. Position adapter on to case. Ensure shift gates clear the adapter assembly. Ensure shift rails and rear bearings align with adapter bores.

Fig. 2 Adapter Bolt Hole Pattern:

39. Install the three sizes of bolts (35mm, 55mm and 110mm) into their appropriate holes in the adapter. Torque bolts to 11-16 ft lbs (14-21 Nm).
40. Install neutral return plungers, springs and bolts into adapter assembly. The longer plunger with the slot for the detent ball is installed on the right side of the adapter.
41. Position shift gates so roll pin holes in the gates and rails align. Install roll pins through the access holes. Install access hole plugs.
42. Position pan and new gasket on to case. Install bolts and torque to 11-16 ft lbs (14-21 Nm). Do not over torque the bolts. Install drain plug and torque to 25-32 ft lbs (33-43 Nm).
43. Insert plunger detent ball and spring into hole above the neutral return plunger in the adapter case.
44. Ensure the stopper bracket assembly on the cover for the transfer case adapter moves smoothly. Position a new gasket on to the adapter and install housing cover. Torque attaching bolts to 11-16 ft lbs (14-21 Nm).
45. Install backup lamp switch and shift indicator light switch into adapter.
46. Fill transmission assembly with suitable lubricant, then install and torque fill plug to 22-25 ft lbs (29-33 Nm).
47. Position clutch slave cylinder onto input shaft. Position clutch housing on to transmission case and tighten nuts.