Assembly
Fig.13
Fig.14
Assembly
NOTE: If a bearing is not used, be sure that a protector is used over the 3-4 synchronizer to prevent jamming the 4th blocking ring onto the cone seat.
1. Coat all parts especially the bearings, with specified transmission lubricant to prevert scoring when the transmission is first put into operation.
2. Position the countershaft gear assembly thrust washers in the transmission case
3. Position the countershaft gear assembly (with dummy shaft tool installed) in the transmission case. Use care so that no roller bearings are lost, and so that the thrust washers are not moved out of position.
4. Carefully, drive out the countershaft gear assembly dummy shaft by installing the countershaft from the rear of the transmission case. Position the slot in the rear of the countershaft so that it can be engaged by the shaft retainer.
5. Position the reverse idler gear assembly in the transmission case, and install the reverse idler gear shaft. Position the slot in the rear of the shaft so that it can be engaged by the shalt retainer.
6. Install the countershaft and reverse idler gear shaft retainer.
7. Load the 22 pilot bearing rollers in the inner end of the input shaft (use petroleum jelly to keep the pilot bearings in position). Position the input shaft assembly in the transmission case and install the blocking ring on the input shaft.
8. Install the output shaft assembly in the transmission case. Use care so that the pilot bearing rollers are not permitted to drop out of the Input shaft.
9 Install a dummy bearing (Tool T75L-7O25-Q or equivalent) on the transmission input shaft. This tool is necessary to keep the input and output shafts in alignment when installing the output shaft bearing.
10. Assemble the locating snap ring to the outer race of the output shaft bearing in the groove provided.
11. Install the output shaft bearing using the tools T75L-7025-B, L (or equivalent) as shown in Fig. 13.
12. Install the flat washer against the rearward face of the output shaft bearing. (The properly installed washer will be external to the main body of the transmission.)
13. Install a snap ring at the rearward surface of the washer in the output shaft groove provided.
14. Remove the dummy bearing from the input shaft.
15. Install the input shaft bearing using the Tools T75L-7025-B, K- R, S (or equivalents) as shown in Fig. 14 and install the snap ring. Use the thickest select fit snap rings which will fit on the bearing.
16. Install the input shaft bearing spacer and retainer gasket and retainer. Tighten the bolts to specification.
17. Position the speedometer drive gear (and spacer if used) on the output shaft over lock ball and install the speedometer drive gear retaining snap ring.
18. Using a new gasket install the output shaft bearing retainer (or extension housing). Tighten the bolts to specification.
19. Lubricate the extension housing bushing and seal and the U-joint flange with Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent.
20. Install the U-joint flange. Lock the transmission in two gears and tighten the retaining nut to specifications.
21. Install the gear shift housing assembly (with Standard Transmission Lubricant (SAE 80W), and unit shifted into second gear) on the transmission and tighten the cover bolts to specification.
22. Fill the transmission to the proper level with Standard Transmission Lubricant (SAE 80W) D8DZ-19C547-A (ESP-MC83C) or equivalent. Add 1/4 liter (1/2 pint) of lubricant through the speedometer cable hole in the rear transmission extension housing.