Upper Case, Gearshift Shafts and Gearshift Forks

REMOVE OR DISCONNECT





1. Backup lamp switch from upper case.





2. Three locating spring bolts, three set washers, three locating springs and three locating balls from upper case.

Important: When removing any gearshift shaft, the interlock system will prevent gearshift shaft removal unless the other two gearshift shafts are in the neutral position.

3. Place all three gearshift shafts in the neutral position.





4. Low speed gearshift fork roll pin, low speed gearshift fork and low speed gearshift shaft from upper case.
5. High speed gearshift fork roll pin, high speed gearshift fork and high speed gearshift shaft from upper case.
6. Reverse gearshift shaft from upper case.
7. Reverse gearshift fork roll pin and reverse gearshift fork from reverse gearshift shaft.
8. Two rubber plugs and two interlock balls from upper case.
9. Interlock pin from high speed gearshift shaft.





Inspect
- Gearshift shafts for wear. Pay particular attention to the locating and gearshift lever grooves in the gearshift shafts. Replace any gearshift shaft that exhibits excessive wear or damage. Insert each gearshift shaft into upper case and check for smooth operation while working back and forth. If any gearshift shaft binds, correct by carefully sanding contact surfaces with emery cloth.

Measure
^ Tool Required:
- J 26900-7 Dial Caliper





1. Clearance fork-to-sleeve clearance using a feeler gage. If clearance exceeds 1.0 mm (0.039 inch), replace the fork and synchronizer sleeve as necessary.





2. Locating spring length using J 26900-7. Standard locating spring length is 24.0 to 27.0 mm (0.945 to 1.063 inch). If a spring is less than 24.0 mm (0.945 inch), replace it.

INSTALL OR CONNECT





Important: The reverse gearshift fork roll pin is 5 mm (0.187 inch) longer than the low speed and high speed gearshift fork roll pins. The clearance between the low speed and high speed gearshift forks and the upper case is not sufficient for the removal of a roll pin longer than 25 mm (0.98 inch). If the reverse gear shift fork roll pin is installed in the low speed or high speed gearshift fork, the reverse gearshift fork roll pin will contact the upper case during any future disassembly. This may inhibit transmission operation as well as making any gearshift fork removal impossible.





1. Reverse gearshift fork to reverse gearshift shaft; secure with reverse gearshift fork roll pin.

Important: When installing the reverse gearshift fork roll pin, DO NOT press the roll pin in until it is flush with the gearshift fork. Allow a 3.5 to 4.5 mm (0.138 to 0.177 inch) protrusion above the gearshift fork.





2. Reverse gearshift shaft and interlock ball into upper case.
3. Place the reverse gearshift shaft into the neutral position.
4. Fit interlock pin into high speed gearshift shaft.





5. High speed gearshift shaft into upper case with high speed gearshift fork; secure with high speed gearshift fork roll pin.
6. Interlock ball into upper case.
7. Place the high speed gearshift shaft into the neutral position.
8. Low speed gearshift shaft into upper case with low speed gearshift fork; secure with low speed gearshift fork roll pin.
9. Apply Loctite RTV silicone sealer, or equivalent, to the two rubber plugs.





10. Two rubber plugs into upper case.

Clean





- Interlock system operation. In 1st or 2nd gear position, a 3rd-to-4th or 5th-to-reverse gearshift should not be possible. In reverse gear position, a 1st-to-2nd or 3rd-to-4th gearshift should not be possible.





11. Three locating balls, three locating springs, three set washers and three locating spring bolts into upper case.
- Tighten locating spring bolts to 28 Nm (21 ft. lbs.).
12. Backup lamp switch into upper case.
- Tighten backup lamp switch to 20 Nm (15 ft. lbs.).