Assembly/Disassembly

DISASSEMBLE

1. Remove clutch release fork and throwout bearing from clutch housing.
2. Remove back-up light switch, shift retainer and restrictor pins, Note difference in pins to aid reassembly.
3. Remove clutch housing attaching bolts and the clutch housing.

Fig. 1 Screw plug location:

4. Remove screw plug from side of adapter housing.
5. Remove spring and detent ball, using a suitable magnet.
6. Remove 5 adapter housing attaching bolts and one nut.
7. Remove shift lever housing set bolt, then the lock plate.
8. Remove plug from rear of shift fork shaft, then pull shaft from housing.
9. Rotate and remove select lever.
10. Remove extension housing retaining bolts and nuts, then the extension housing. Leave gasket attached to intermediate plate.
11. Remove the front bearing retainer and outer snap rings from transmission case.
12. Using a plastic mallet or equivalent, separate transmission case from intermediate plate.

Fig. 2 Mounting intermediate plate:

13. Mount intermediate plate in a vise using bolts, washers and nuts as shown. Increase of decrease the number of washers so bolt tip and outer surface of nuts are flush.

Fig. 3 Screw plug, locking balls & springs replacement:

14. Remove screw plug, locking balls and springs from intermediate plate.

Fig. 4 Spring, pins & E-ring replacement:

15. Using a hammer and punch, drive out the slotted spring pins, then remove the E-rings from the shift rails with suitable pliers. The locking ball from the reverse shift head and the locking ball and pin from the intermediate housing will drop out from their respective holes.

Fig. 5 No. 4 shift fork shaft, locking ball & 5th gear fork replacement:

16. Pull No. 4 shift fork shaft from intermediate plate, disengage locking ball, then remove shaft and 5th gear fork.

Fig. 6 No. 5 shift fork shaft & reverse shift head replacement:

17. Remove No. 5 shift fork shaft and the reverse shift head. Remove interlock pins.

Fig. 7 No. 3 shift fork shaft & interlock pins replacement:

18. Remove No. 3 shift fork shaft and interlock pins.

Fig. 8 No. 1 shift fork shaft & interlock pin replacement:

19. Remove No. 1 shift fork shaft and the interlock pin.

Fig. 9 No. 2 shift fork shaft & Nos. 1 & 2 shift forks replacement:

20. Remove No. 2 shift fork shaft, then the No. 2 and No.1 shift forks.

Fig. 10 Reverse idler gear shaft stopper, reverse idler gear, shaft & reverse shift arm replacement:

21. Remove reverse idle gear shaft stopper, reverse idler gear and shaft, then the reverse shift arm from shift arm bracket.

Fig. 11 Counter 5th gear thrust clearance measurement:

22. Measure counter fifth gear thrust clearance with a feeler gauge as shown. Clearance should be 0.004-0.012 inch.
23. Lock output shaft, then remove countershaft locknut.

Fig. 12 No. 5 gear spline piece, synchronizer ring, needle bearing & counter 5th gear & hub replacement:

24. Use puller J-22888 or equivalent to remove No. 5 gear spline piece, synchronizer ring, needle bearings and counter fifth gear and hub sleeve.
25. Remove spacer and ball, then the reverse shift arm bracket.
26. Remove rear bearing retainer bolts, then the snap ring.

Fig. 13 Input, output & countershafts replacement:

27. Remove output shaft, input shaft and countershaft from intermediate plate by pulling on countershaft, while tapping on intermediate plate.
28. Separate input shaft from output shaft, then remove countershaft rear bearing from intermediate plate.

ASSEMBLE

1. Apply grease to input shaft needle bearings then install bearings into shaft.
2. Install output shaft into intermediate plate by pulling on shaft while tapping on plate with a plastic mallet.
3. Connect input and output shafts, ensuring synchronizer ring slots align with shifting keys.
4. Install countershaft into intermediate plate, the drive bearing into plate.
5. Install output shaft rear bearing retainer and snap ring. Torque bearing retainer attaching screws to 13 ft. lbs.

Fig. 18 Reverse shift arm bracket installation:

6. Install reverse shift arm bracket onto intermediate plate then torque retaining bolts to 13 ft. lbs.
7. Install ball and spacer onto countershaft.
8. Install shifting keys and No. 3 hub sleeve onto counter fifth gear. Install shifting key springs under keys, ensuring end gaps are not in alignment.
9. Apply gear lubricant to needle bearing, then install counter fifth gear, hub sleeve and needle bearing on to countershaft.
10. Assemble synchronizer ring to No. 5 gear spline piece, ensuring ring slots align with shifting keys the install assembly onto countershaft.
11. Lock output shaft and install locknut onto countershaft. Torque locknut to 90 ft lbs. and stake nut to prevent movement.
12. Measure counter fifth gear thrust clearance with a feeler gauge. Clearance should be 0.004-0.012 inch.
13. Install reverse shift arm into reverse shift arm bracket, then the reverse idler gear onto shaft.
14. Align reverse shift arm shoe to reverse idler gear groove, then insert reverse idler gear shaft into intermediate plate.
15. Install reverse idler gear shaft stopper and torque retaining bolt to 13 ft. lbs.
16. Position No. 1 and 2 shift forks into grooves of hub sleeves, then insert No. 2 shift fork shaft through intermediate plate and into shift forks.
17. Apply grease to interlock pins, then install pins into intermediate plate and No. 2 shift fork shaft hole.
18. Install No. 1 shift fork shaft through intermediate plate and into No. 1 shift fork.
19. Apply grease to interlock pins, then install pins into intermediate plate and No. 1 shift fork hole.
20. Install No. 3 shift fork shaft through intermediate plate and into reverse shift arm.
21. Install reverse shift head onto No. 5 shift fork shaft, then insert shaft through intermediate plate, ensuring No. 3 shift fork shaft engages reverse shift head.
22. Install locking ball into reverse shift head hole, then shift No. 3 hub sleeve into fifth gear position.
23. Position No. 3 shift fork into No. 3 hub sleeve groove, then insert No. 4 shift fork shaft into No. 3 shift fork and the reverse shift arm.
24. Install locking ball into intermediate plate, then insert No. 4 shift fork shaft through intermediate plate.
25. Pull No. 1 shift fork shaft into first speed position, then check interlock by trying to move all other shafts. Shafts should not move.
26. Install new slotted spring pins into each shift fork, the reverse shift arm and the reverse shift head, then install the two shift fork shaft E-rings.
27. Install locking balls and springs into intermediate plate, then apply sealer to screw plugs and install into intermediate plate. Torque screw plugs to 14 ft. lbs. Install short spring into tower of intermediate plate.
28. Remove intermediate plate from vise. Remove bolts, washers and nuts.
29. Align each bearing outer race, each shift fork end and reverse idler gear with the holes in the transmission case, then connect case to intermediate plate.
30. Install two new snap rings, then the front bearing retainer and gasket. Apply sealer to bearing retainer bolts, then install bolts and torque to 12 ft. lbs.
31. Install new gasket onto intermediate plate, then install adapter housing and bolts. Torque bolts to 27 ft. lbs.
32. Install shift lever housing.
33. Insert shift lever into housing, then install shift lever housing bolt and lock plate. Torque bolt to 28 ft. lbs. and lock the locking plate.
34. Install plug at rear of shift fork shaft. Torque plug to 13 ft. lbs.
35. Install detent ball and spring, then apply sealer to screw plug and install into side of adapter housing.Torque screw plug to 14 ft. lbs.
36. Ensure input and output shafts can be rotated and shifting may be accomplished easily.
37. Install restrictor pins and torque to 20 ft. lbs.
38. Install shift lever retainer, gasket and attaching bolts. Torque bolts to 13 ft. lbs.
39. Install back-up light switch and torque to 27 ft. lbs.
40. Install clutch housing and retaining bolts, then torque bolts to 27 ft. lbs.