Transmission Case Assembly
Assembly - Transmission CaseCAUTION: Except for the gearshift lever attaching bolts and filler plug, all bolts and threaded holes used in the T4 transmission have metric dimensions, IDo not attempt to substitute with a different thread-type or size bolt if an original bolt is damaged or lost.
Coat the countershaft front bearing outer cage with Loctite 601, or equivalent, and install the countershaft front bearing (flush with.the case) with an arbor press.
Coat the countershaft tabbed thrust washer with petroleum jelly. Install the thrust washer so that the tab engages the corresponding depression in the case.
Turn the transmission case so that it is on its end and install the countershaft in the front bearing bore.
Install the countershaft rear bearing spacer (21).
Coat the countershaft rear bearing with petroleum jelly and install the bearing with Installation Tool J-28895 and a hammer.
NOTE: When correctly installed, the countershaft rear bearing extends 3 mm (0.125 in.) beyond the case surface.
Position the reverse idler gear (24) in the transmission case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft (23) from the rear of the case and install the retaining roll pin (22) in the shaft.
Install the assembled output shaft in the transmission case.
Install the clutch shaft front bearing on the clutch shaft with Tool J-6133-O1 and an arbor press.
Coat the 15 pilot roller bearings (17) with petroleum jelly and install them on the clutch shaft.
Install the thrust bearing and race (16) on the clutch shaft.
Install the fourth gear blocking ring on the output shaft.
Install the output shaft rear bearing race.
Install the clutch shaft in the transmission case and engage the shaft in the third-fourth gear synchronizer sleeve and blocking ring.
Install a replacement oil seal in the front bearing cap with Tool J-26625.
Install a replacement rear oil seal in the adapter housing with Tool J-29184.
Install the front bearing race in the front bearing cap. Do not install the shims at this time.
Install the front bearing cap. Do not apply sealant at this time.
Coat the reverse gear shift lever pivot pin bolt threads with Loctite sealant. Install the reverse gear shift lever, pivot pin bolt and retaining C-clip (9). Ensure that the reverse gear shift lever fork is engaged in the reverse idler gear. Tighten the shift lever pivot pin bolt with 58 Nm (43 ft-lbs) torque.
Coat the countershaft rear bearing race and thrust bearing with petroleum jelly and install them in the adapter housing.
Temporarily install the adapter housing. Do not apply sealant or tighten the bolts with the final torque at this time.
Turn the transmission case on its end. Position Dial Indicator Tool J-8001 on the adapter housing with the indicator stylus on the end of the output shaft.
Rotate the clutch and output shafts and zero the dial indicator pointer.
Pull upward on the output shaft until the end play is eliminated. Note the end play on the dial indicator.
NOTE: To completely eliminate the output shaft and clutch shaft end play, the bearings must be preloaded from 0.03 to 0.13 mm (0.001 to 0.005 in.).
Select a shim pack that is 0.03 to 0.13 mm (0.001 to 0.005 in.) thicker than the end play measured above.
Place the transmission horizontally on a workbench and remove the front bearing cap and front bearing race.
Add shims to the bearing cap to obtain the necessary preload. Install the bearing race in the cap.
Apply a bead of RTV sealant on the transmission case mating surface for the front bearing cap. Install the front bearing cap with the reference marks (scribed during disassembly) aligned. Tighten the retaining bolts with 18 Nm (13 ft-lbs) torque.
Measure the end play. There must be no end play.
Remove Dial Indicator Tool J-8001 from the adapter housing.
Remove the adapter housing.
Move the shift forks on the transmission cover and synchronizer rings inside the transmission to the neutral position.
Apply a bead of RTV sealant to the transmission case mating surface for the cover.
Lower the cover, at a slightly oft center attitude, onto the transmission case while aligning the shift forks and synchronizer sleeves. Center the cover on the transmission case to engage the reverse gear lever fork and install the two dowel bolts in the cover. Install the remaining bolts and tighten all the cover bolts with 12 Nm (9 ft-lbs) torque.
NOTE: The offset lever-to-shift rail roll pin hole will be in a vertical position when the cover is installed correctly.
Apply a bead of RTV sealant on the adapter housing-to-transmission case mating surface.
Install the adapter housing over the output shaft and shift rail at a position where the shift rail just enters the shift cover opening.
Install the detent spring (6) in the offset lever (2). Place the detent ball (5) in the neutral guide plate detent. Apply force on the detent ball with the detent spring and offset lever, slide the Qffset lever onto the shift rail and seat the adapter housing against the transmission case.
NOTE: The offset lever and shift rail roll pin holes should be aligned and in a vertical position at this time.
Install and tighten the adapter housing retaining bolts with 27 Nm (20 ft-lbs) torque.
Install the roll pin (1) in the offset lever (2) and shift rail (3).
Install the damper sleeve in the offset lever.
Coat the backup lamp switch threads with RTV sealant, install the switch in the; transmission case and tighten with 20 Nm (15 ft-lbs).
Install the drain bolt.