Assembly
Transmission
Assembly
1. Install the countershaft cluster gear.
2. Position the input shaft.
3. NOTE: Verify the 4th gear synchronizer blocking ring is in place.
Install the output shaft.
4. Position the input shaft and output shaft together.
5. Install the countershaft front and rear roller bearings.
6. Install the output shaft rear bearing and input shaft bearing.
7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
Install the rear bearing retainer and the 6 rear bearing retainer bolts.
- Tighten to 22 Nm (16 lb-ft).
8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.
Using the Clutch Housing Oil Seal Installer, install the front cover oil seal.
9. Position the transmission with the clutch housing facing up.
10. Using the Depth Micrometer, measure the input shaft bearing race depth.
- Record the reading on Line 2 of the Selective Shim Equation Chart.
11. Using the Depth Micrometer, measure the front bearing retainer depth.
- Record the reading on Line 1 of the Selective Shim Equation Chart.
12. Calculate and select the correct output shaft shim. Refer to the Output Shaft Shim Selective Chart.
Selective Shim Equation Chart
Output Shaft Shim Selective Chart
13. Using the Depth Micrometer, measure the countershaft bearing depth.
- Record the reading on Line 1 of the Countershaft Spacer Equation Chart.
14. Using the Depth Micrometer, measure the countershaft bearing retainer depth.
- Record the reading on Line 2 of the Countershaft Spacer Equation Chart.
15. Calculate and select the correct countershaft spacer. Refer to the Countershaft Spacer Selective Chart.
Countershaft Spacer Equation Chart
Countershaft Spacer Selective Chart
16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.
Position the bearing shim, the fluid baffle and the countershaft spacer onto the front bearing retainer.
- Using gasket maker, apply a thin coat to the sealing surface of the case and the front bearing retainer.
17. NOTICE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.
NOTE: Apply silicone sealant to the bolt threads.
Install the front bearing retainer and the 6 front bearing retainer bolts.
- Tighten to 19 Nm (168 lb-in).
- Remove the tape from the input shaft splines.
18. Position the front oil passage.
19. NOTE: Apply silicone sealant to the bolt threads.
Install the front oil passage bolt.
- Tighten to 9 Nm (80 lb-in).
20. Install the output shaft 5th gear.
21. Install the locking ball.
22. Install the race and the 5th gear split needle bearing on the countershaft.
23. Install the countershaft 5th gear and the countershaft 5th gear synchronizer blocking ring.
24. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
Install the 5th/reverse shift rail, the shift fork, and the synchronizer as an assembly.
25. Install the 5th/reverse shift lever into the case.
26. Install the counter lever shaft assembly.
- Tighten the nut to 45 Nm (33 lb-ft).
- Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.
27. Install the 5th/reverse gear shift rail bolt.
- Tighten to 25 Nm (18 lb-ft).
28. Install the synchronizer split washer.
29. Using a feeler gauge, check the clutch hub end play.
- If the clutch hub end play is not within specification, select and install the correct split washer.
Split Washer Select Chart
30. The reverse gears are not serviced separately. A kit consisting of the output shaft reverse gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the kit must be installed. The replacement gears are not compatible with the existing gears.
1. Output shaft reverse gear.
2. Countershaft reverse gear.
3. Reverse idler gear.
31. Install the following:
- Thrust washer
- Two countershaft reverse gear needle bearings
- Countershaft reverse gear
32. Measure the countershaft reverse gear end play.
- Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
- Determine the correct thrust washer to obtain the correct end play. Remove the reverse gear and install the appropriate thrust washer. Reinstall the reverse gear.
Thrust Washer Select Chart
33. Install the output shaft spacer.
34. Install the output shaft reverse gear.
35. Install the reverse idler gear.
36. NOTE: Reverse idler shaft bolt must be installed within 4 minutes after applying the thread sealant with PTFE.
Install the reverse idler shaft bolt.
- Tighten to 98 Nm (72 lb-ft).
- Apply thread sealant to the reverse idler shaft bolt threads.
37. Using the Bearing Shaft Collar Installer (308-031), Bearing Shaft Collar Installer (308-035), Bearing Tube Remover/Installer and the Gear Spacer, install the output shaft rear bearing.
38. Install the thrust washer and the countershaft rear bearing.
39. Lock the transmission into 1st and 3rd gear.
40. Install a new countershaft locknut.
- Tighten to 162 Nm (119 lb-ft).
41. Using the Transmission Shaft Locknut Socket, install a new output shaft rear bearing locknut.
- Tighten to 216 Nm (159 lb-ft).
42. Using the Locknut Staking Tool, stake the output shaft rear bearing locknut and the countershaft locknut.
43. Install the locating ball, tone wheel and the tone wheel snap ring.
44. Apply gasket maker to the mating surface of the extension housing. Install the extension housing and the 8 extension housing bolts.
- Tighten to 39 Nm (29 lb-ft).
45. Using the Transmission Extension Housing Oil Seal Installer, install the extension housing seal.
46. Place the synchronizer sleeves in neutral.
47. Install the case cover gasket.
48. Install the shift control housing and the 10 bolts.
- Tighten to 19 Nm (168 lb-in).
