Overhaul (Assembly)

Transmission

Part 1:

Part 2:

Part 3:

Special Tool(s)





Material

1. CAUTION: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure.

Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant during reassembly.








2. Index-mark the countershaft in relation to the oil pump slot.





3. Position the countershaft to the mainshaft on the Gear Pack Assembly Fixture.





4. Install the countershaft rear bearing spacer. The countershaft rear bearing spacer can be installed either way.





5. Install the first/second and third/fourth shift fork and shift rail assemblies.
^ The detent groove on the rail faces upward or to the output shaft.
^ All shift forks and rails use double roll pins.





6. Install the interlock plate.
^ The stamped part numbers on the interlock plate must face toward the input shaft.





7. Install and position the intermediate housing on the mainshaft, the countershaft, and the shift rails.
^ Make sure the detents are clear of the bore area on the intermediate housing.





8. Install the interlock plate bolts.





9. Assemble the fifth gear synchronizer assembly.





10. Install the fifth gear synchronizer assembly.
^ Install the fifth gear synchronizer with the snap ring on the synchronizer body facing down against the intermediate housing.
^ The fifth gear synchronizer will slide into place and does not require heat to install.





11. CAUTION: To prevent damage, do not heat the countershaft bushing higher than 150°C (300°F) maximum.

Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.





12. NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.

Install the countershaft needle bearing.





13. Install the fifth gear.





14. Install the countershaft rear thrust washer and a new snap ring.
^ The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
^ Install the snap ring with the small holes upward.
^ Make sure the snap ring is completely seated, with one tab of the snap ring under the gear tooth.





15. For vehicles equipped with a 6.0L engine, install the low gear thrust washer.





16. Install the two mainshaft low gear needle bearings.





17. Install low gear.





18. Install the low and reverse synchronizer assembly and synchronizer ring.
^ Install the low/reverse gear synchronizer with the shoulder of the sliding sleeve facing down to the low gear.
^ The low/reverse synchronizer body will slide into place and does not require heat to install.





19. CAUTION: To prevent damage, do not heat the reverse gear bushing higher than 150°C (300°F) maximum.

Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.





20. NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.

Install the mainshaft needle bearing.





21. Install the reverse gear. Pull the synchronizer sliding sleeve into the neutral position.





22. CAUTION: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (300°F) maximum.

Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the special tools, install the output bearing thrust washer.





23. CAUTION: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (300°F) maximum.

Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the special tools, install the rear mainshaft output bearing.





24. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at fifth gear.
^ If not within specifications, disassemble and reinspect.





25. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at low gear.
^ If not within specifications, disassemble and reinspect.





26. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at reverse gear.
^ If not within specifications, disassemble and reinspect.





27. NOTE: The snap ring is used on 4-wheel drive vehicles only.

Install a new snap ring. The snap ring is a selective fit.
^ The correct snap ring should completely fill the groove when seated.
^ Install the snap ring with the small holes upward.





28. NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and shift rails.

NOTE: Move the interlock plate into the fifth gear position.

Install the fifth gear shift fork and the shift rail.





29. Using a 5-mm (3/16-inch) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
^ Do not hit the sealing surface of the intermediate plate.
^ Make sure the slot of the roll pin is facing away from the shift rail.





30. NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and rails.

NOTE: Move the interlock plate into the low/reverse position.

Install the low/reverse gear shift fork and the shift rail.





31. Using a 5-mm (3/16-inch) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
^ Make sure the slot of the roll pin is facing away from the shift rail.





32. Install the four shift detent springs and four new detent plugs.
^ Apply gasket maker to the detent plugs before installing.





33. Install the main shift rail, aligning the center of the interlock driver with the center of the interlock plate. The part numbers on the main shift rail, shift position block and shift finger face the output side of the transmission. The roll pin groove on the main shift rail with the shorter distance from the end faces the output end.





34. Install the lower shift finger and a new large roll pin, then Install a new small roll pin.
^ Make sure the lower shift finger cup is down.
^ Install the large roll pin with the opening away from the gearset.
^ Make sure the center of the interlock driver is aligned with the center of the interlock plate before installing the small pin.
^ Install the small roll pin with the opening 180 degrees from the opening in the large roll pin. The roll pin should extend equally from both sides when properly installed.





35. Install the main shift rail driver and a new large roll pin, then install a new small roll pin.
^ Install the large roll pin with the opening away from the gearset.
^ Install the small roll pin with the opening 180 degrees from the opening in the large roll pin.

36. NOTE: Only install the bearing cups in the main case. The following bearing preload adjustment procedure will determine the thickness of the shim to be used.

NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50 - 101 mm (2 - 4 inches), to prevent damage to the input shaft.

Place the main case on the floor. Align the oil pump center shaft with the slot in the countershaft.





37. NOTE: Do not apply sealer at this time.

NOTE: Do not damage the input shaft when removing it from the Gear Pack Assembly Fixture.

NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the main case.

Using a suitable lifting device, a suitable chain and two S-hooks, lift the intermediate housing and gear assembly into the case.
^ Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
^ Lightly tap the intermediate housing onto the transmission case.





38. Install the bolts.
^ Early production vehicles will have three bolts.





39. Install the special tools to measure countershaft clearance.
^ Mount the indicator stand to the intermediate housing.
^ Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the countershaft.
^ Zero the dial indicator.





40. NOTE: The tool is installed on the PTO opening.

Using the special tool, measure for countershaft clearance.
^ Lift up on the third gear counter.
^ Observe the dial indicator reading.
^ Add preload specification 0.02 mm (0.00079 inch) and 0.09 mm (0.0035 inch) to the dial indicator reading to determine shim thickness range. Countershaft clearance + 0.02 mm (0.00079 inch) Preload = Shim size. Countershaft clearance + 0.09 mm (0.0035 inch) Preload = Shim size. Choose the shim between the calculated values for the correct preload.





41. Install the special tools to measure mainshaft clearance.
^ Mount the indicator stand to the intermediate housing.
^ Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the mainshaft.
^ Zero the dial indicator.





42. Lifting up on the mainshaft, measure the mainshaft clearance.
^ Lift up on low gear.
^ Observe the dial indicator reading.
^ Add preload specification 0.02 mm (0.00079 inch) and 0.09 mm (0.0035 inch) to the dial indicator reading to determine shim thickness. Measure the thickness of the input shaft oil dam bearing ring at three places and subtract the highest dimension. Mainshaft clearance (-) the thickness of the oil dam + 0.02 mm (0.00079 inch) Preload Shim size. Mainshaft clearance (-) the thickness of the oil dam + 0.09 mm (0.0035 inch) Preload = Shim size. Choose the shim between the calculated values for the correct preload.





43. Remove the special tools, then remove the bolts.





44. Using a suitable lifting device, a suitable chain and two S-hooks, lift the intermediate housing and gear assembly out of the case.
^ Place the S-hooks in the area where the bolts were removed.





45. Using the special tools, remove the input shaft bearing cup.





46. Using the special tools, remove the countershaft bearing cup.





47. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.

Install the new shim, the new input shaft oil dam bearing ring and the oil trough into the bearing cup bore, then using the special tools, install the input shaft bearing cup.
^ Using the clearance measurement plus the preload, select the appropriate shim and input shaft oil dam bearing ring.





48. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.

Install the new shim, then using the special tools, install the countershaft bearing cup.
^ Using the clearance measurement plus the preload, select the appropriate shim.

49. CAUTION: Use an oil stone or sanding block to clean the intermediate plate and main case mating surfaces.

CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than ten minutes to tighten the two bolts due to the rapid cure time of the sealant.

Thinly coat the rear sealing surface of the case and the front sealing surface of the intermediate housing with gasket maker.





50. NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50 - 101 mm (2 - 4 inches), to prevent damage to the input shaft.

NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the case.

Install the intermediate housing and gear assembly into the case.
^ Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
^ Lightly tap the intermediate housing onto the transmission case.





51. Install the bolts. Apply threadlock and sealer to the intermediate housing bolts.





52. CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than ten minutes to tighten the bolts due to the rapid cure time of the sealant.

Thinly coat the rear sealing surface of the intermediate housing and the extension housing with gasket maker. Install the extension housing.





53. Apply threadlock and sealer to the threads of the main shift detent. Install the detent plunger and the main shift detent.





54. NOTE: Cross tighten the bolts.

Apply threadlock and sealer to the threads of the PTO cover bolts. Install a new gasket and the PTO cover.





55. Using the special tool, install a new input oil seal.
^ Coat the outer diameter of the new input oil seal with gasket and trim adhesive.
^ Coat the inner diameter of the new input oil seal with MERCON.





56. Apply threadlock and sealer to the threads of the guide tube bolts. Install the guide tube.





57. Install the release lever and clutch release hub and bearing.
^ Lubricate the ball stud and the clutch release lever. Only apply grease where the clutch release lever comes in contact with the pivot and the release hub and bearing.








58. Coat the outer diameter of the new output oil seal with gasket and trim adhesive. Using the special tool, install a new output oil seal.





59. NOTE: This step is for 2-wheel drive vehicles only.

Apply Threadlock 262 to the threads of the transmission flange lock nut. Using the holding fixture and the mainshaft locknut socket, install the transmission flange and a new pinion flange lock nut.
60. Install the shifter.
^ Shift the transmission through all gears to make sure gears shift correctly.
61. Check transmission preload. Shift the transmission into reverse and rotate the mainshaft.
^ Drag torque should be 2 - 8 Nm.
62. Remove the shifter for installation.