Shift Forks and Mainshaft Installation

1. Install new sector shaft O-ring and bushing.





2. Install shift sector in case. Lubricate sector shaft with transmission fluid before installation.





3. Install range lever, washer, and nut on sector shaft. Tighten range lever nut to 27 - 34 Nm (20 - 25 ft. lbs.) torque.





4. Assemble and install range fork and hub. Be sure hub is properly seated in low range gear and engaged to the input gear.
5. Align and insert range fork pin in shift sector slot.





6. Install assembled mainshaft. Be sure shaft is seated in pilot bearing and input gear.
7. Install new pads on mode fork if necessary.





8. Insert mode sleeve in mode fork mode fork. Be sure long side of sleeve is toward long end of shift rail.





9. Install assembled mode fork and sleeve. Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub.
10. Rotate sector to Neutral position.





11. Install new O-ring on detent plug.
12. Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
13. Install detent plunger, spring and plug.
14. Verify that plunger is properly engaged in sector.