Adapter/Extension Housing and Front Bearing Retainer
DISASSEMBLY1. Drain transmission lubricant, if necessary.
2. Remove release bearing and lever.
Fig. 19:
3. Remove clutch housing bolts and remove housing.
4. Remove vehicle speed sensor and speedometer adapter, if necessary.
5. Remove bolts holding shift tower to transmission case.
Fig. 17:
6. Remove shift tower from transmission case.
Fig. 18:
7. Remove shift tower gasket from shift tower or transmission case.
Fig. 20:
8. Remove reverse shift head detent ball plug.
Fig. 21:
Fig. 22:
9. Remove detent ball spring and ball with pencil magnet.
Fig. 23:
10. Remove shift arm retainer bolt.
Fig. 24:
11. Remove shift arm restrictor pins.
Fig. 25:
12. Remove shift lever shaft plug.
Fig. 26:
13. Remove shifter shaft with large magnet.
14. Remove the shift arm from the adapter housing.
Fig. 27:
15. Remove adapter/extension housing bolts.
Fig. 28:
16. Loosen adapter/extension housing by tapping it loose with plastic mallet.
Fig. 29:
17. Remove adapter/extension housing.
18. On 4x2 transmissions;
a. Remove speedometer gear retaining snap-ring from output shaft.
b. Remove speedometer gear from output shaft and remove speedometer gear lock ball from output shaft.
Fig. 30:
c. Remove speedometer drive gear locating snap-ring.
19. Remove the bolts holding the front bearing retainer to the transmission case.
Fig. 31:
20. Remove the bearing retainer from transmission case.
Fig. 32:
21. Remove input shaft bearing snap-ring.
Fig. 33:
22. Remove cluster gear bearing snap-ring.
Fig. 34:
23. Separate intermediate plate and transfer case by tapping them loose with plastic mallet.
Fig. 35:
24. Separate the intermediate plate from the transmission case.
ASSEMBLY
1. Remove any residual sealer from transmission case, intermediate plate, adapter/extension housing, and front bearing retainer.
Fig. 36:
2. Apply a 1/8 to 3/16 inch wide bead of Threebond8 Liquid Gasket T131281, P/N 83504038, as shown, making sure to keep sealer bead to inside of bolt holes.
Fig. 37:
3. Align gear-train and shift rails with mating holes in transmission case and install transmission case to the intermediate plate. Verify that the transmission case is seated on the intermediate plate.
Fig. 38:
4. Install new front bearing snap rings.
5. Apply 1/8 inch wide bead of Threebond Liquid Gasket TB1281, P/N 83504038, to the front bearing retainer sealing surface.
Fig. 39:
6. Install the front bearing retainer and tighten bolts to 17 Nm (12 ft. lbs.).
7. On 4x2 transmissions;
Fig. 40:
a. Install speedometer drive gear locating snap-ring.
b. Install speedometer gear lock ball in output shaft and install speedometer gear onto output shaft.
c. Install speedometer gear retaining snap-ring onto output shaft.
8. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket T131281, P/N 83504038, to sealing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
Fig. 41:
9. Install adapter or extension housing on intermediate plate. Tighten housing bolts to 37 Nm (27 ft. lbs.) torque.
Fig. 42:
10. Position shift arm in shifter tower opening of adapter/extension housing. Be sure that the shifter arm is engaged into the shift rails.
Fig. 43:
11. Start shifter arm shaft in hole in back of adapter/extension housing. Align shift arm and Shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter/extension housing.
12. Rotate the shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft.
Fig. 44:
13. Install the shift arm retainer bolt and tighten to 38 Nm (28 ft. lbs.).
Fig. 45:
14. Install and tighten shifter arm shaft plug to 18 Nm (13 ft. lbs.) torque.
Fig. 46:
15. Install shifter restrictor pins in shift tower and tighten to 27 Nm (20 ft. lbs.).
Fig. 47:
16. Install shift detent ball in detent opening.
Fig. 48:
17. Install detent spring.
Fig. 49:
18. Install detent plug and tighten to 19 Nm (14 ft. lbs.).
Fig. 50:
19. Install shift tower and new gasket on housing. Tighten tower bolts to 18 Nm (13 ft. lbs.) torque.
20. Install new metal O-ring to the backup lamp switch.
21. Install backup lamp switch. Tighten switch to 37 Nm (27 ft. lbs.) torque.
22. Install new seal in adapter/extension housing.
23. Install vehicle speed sensor, if necessary.
24. Install clutch housing, release bearing, release fork and retainer clip.