Internal Components

ASSEMBLE
1. Spring retainers to the synchronizer hub.
2. Synchronizer hub to the synchronizer sleeve with the three struts.
- Align the scribe marks previously made.
3. Main drive synchronizer stop ring to the synchronizer sleeve.

INSTALL OR CONNECT
1. Drive sprocket to the mainshaft.





2. Synchronizer assembly to the mainshaft.





3. Synchronizer snap ring to the mainshaft.





4. Input gear and planetary assembly into the annulus gear using a soft faced hammer.





5. Snap ring to the input bearing.
6. Input shaft bearing retainer and input bearing retainer bolts to the front case half.
- Apply RTV, or the equivalent, to bearing retainer mating surfaces.
- Apply Thread-locker, or the equivalent to bearing retainer bolts.

Tighten
- Input bearing retainer bolts to 19 Nm (14 lb. ft.).





7. Three bolts securing encoder motor to the front case.

Tighten
- Encoder motor bolts to 18 Nm (13 lb. ft.).

8. Range shift hub into the front case half.
9. Front output shaft to the front case half.
10. Driven sprocket to the chain.





11. Drive chain onto the drive sprocket located on the mainshaft.
- Mainshaft assembly, driven sprocket, and drive chain are installed into the front case half as an assembly.
12. Driven gear snap ring to front output shaft.
13. Mode shift fork onto shift rail.
14. Mode shift fork assembly through the range shift fork, onto the synchronizer sleeve, and into the front case half.





15. Mode fork shift spring to the shift rail.





16. Oil pump pickup tube, oil tube connector, and pump pickup screen into rear case half.
17. Oil tube O-ring into oil pump.





18. Oil pump to the oil pickup tube.
- Lubricate oil pump pickup tube with automatic transmission fluid before installing into pump.
19. Dowels into front case half.
- Wipe case mating surfaces clean.
- Apply RTV, or the equivalent, to case mating surfaces.
20. Rear case half over mainshaft and onto front case half.





- Be careful not to damage the oil pump while installing the rear case half.
21. Case bolts into case halves.
- Apply Thread-locker, or the equivalent, to the case bolts.
- The two longer case bolts and washers into the doweled case holes.

Tighten
- Case bolts to 31 Nm (23 lb. ft.).





22. Rear vehicle speed sensor rotor snap ring to the mainshaft.





23. Vehicle speed sensor rotor onto the mainshaft.





24. Vehicle speed sensor rotor snap ring.





25. Rear retainer housing and rear retainer bolts to the rear case half.
- Apply Thread-locker, or the equivalent, to the rear retainer housing bolts.
- Rear retainer housing bolts are shouldered.

Tighten
- Rear retainer housing bolts to 41 Nm (30 lb. ft.).





26. Output bearing snap ring to the mainshaft.





27. Rear extension housing and extension bolts to the rear retainer housing.
- Apply RTV, or the equivalent, to the mating surfaces.
- Apply Thread-locker, or the equivalent, to the extension housing bolts.

Tighten
- Bolts to 31 Nm (23 lb. ft.).