Assembly

1. Lubricate countershaft journal and rear bearing with petroleum jelly or gear lubricant.
2. Position mainshaft into the intermediate plate.
3. Tap mainshaft assembly rear bearing into intermediate plate with suitable rubber mallet
4. Install the countershaft through the countershaft bearing journal of the intermediate plate.
5. Align and mesh mainshaft and countershaft gears as much as possible.
6. Install countershaft bearing over the countershaft bearing boss and into the intermediate plate. Be sure to leave the snap-ring groove in bearing facing the rear of the unit. It may be necessary to tap on bearing with a plastic mallet in order to fully seat bearing into intermediate plate.
7. Verify that the mainshaft and countershaft gears are correctly meshed and rotate properly.





8. Install snap-ring to hold output shaft rear bearing into the intermediate plate.
9. Install countershaft rear bearing snap-ring.

NOTE: Coat all shift components with petroleum jelly during assembly. Petroleum jelly will hold components in position during installation.





10. Install interlock pin in reverse shift rail.





11. Install the reverse shift rail in the intermediate plate.
12. Install c-ring to hold the reverse shift rail into the intermediate plate.





13. Install the 1-2 and 3-4 shift forks into the synchronizer sleeves.





14. Install 1-2 shift rail interlock plug in the intermediate plate.





15. Install interlock pin in 1-2 shift rail.





16. Install 1-2 shift rail through intermediate plate and 1-2 shift fork.





17. Install 3-4 shift rail interlock plug into the intermediate plate.





18. Install the 3-4 shift rail through the intermediate plate, 1-2 and 3-4 shift forks.





19. Install new bolts to hold the shift forks to the shift rails.





20. Install c-rings to 1-2 and 3-4 shift rails.





21. Install the fifth gear shift rail lock ball in the intermediate plate.
22. Install the fifth gear shift rail into the intermediate plate.





23. Install reverse idler gear and idler gear shaft. Verify that the notch in the idler shaft is to the rear of the transmission.
24. Position output shaft rear bearing retainer on intermediate plate and into reverse idler shaft notch.





25. Install new bolts to hold retainer to intermediate plate.





26. Install the fifth gear thrust ring lock ball into the countershaft.





27. Install fifth gear thrust ring onto countershaft and over lock ball.





28. Install countershaft fifth gear bearing halves into countershaft fifth gear assembly.





29. Install countershaft fifth gear assembly onto countershaft.





30. Install fifth gear synchronizer ring.
31. Position fifth gear blocker ring onto countershaft. Verify that blocker ring and countershaft splines are aligned.
32. Using a suitable driver and mallet, seat the blocker ring onto the countershaft.
33. Select the thickest snap-ring the will fit into the snap-ring groove of the countershaft.





34. Install snap-ring to hold the countershaft fifth gear assembly onto the countershaft.





35. Install the reverse shift head and rail assembly.





36. Move reverse shift rail forward as far as possible and install fifth gear shift fork onto synchronizer sleeve.





37. Install new bolt to hold fifth gear shift fork to shift rail.





38. Install detent balls and springs into openings in the intermediate plate.
39. Install new lock ball plugs into the intermediate plate. Tighten plugs to 19 Nm (14 ft. lbs.).
40. Install bolts to hold reverse shift arm to the intermediate plate. Tighten bolts to 18 Nm (13 ft. lbs.).