Assembly
ASSEMBLYGEARTRAIN AND SHIFT MECHANISM
Refer to (Fig. 57) while assembling and installing the shift rail components.
NOTE: Shift rail components must be in neutral position when installing check balls and interlock pins. Check balls and interlock pins must be installed in original location.
1. Install 3-4 shift rail into the intermediate plate.
2. Install 1-2 elongated check ball into the intermediate plate (Fig. 58).
3. Install interlock pin into the 1-2 shift rail (Fig. 59).
4. Install 1-2 shift rail into the intermediate plate.
5. Install snap-ring onto 3-4 shift rail.
6. Install reverse check ball into the intermediate plate (Fig. 60).
7. Install interlock pin into the reverse shift rail (Fig. 61).
8. Assemble reverse arm bracket to the reverse fork (Fig. 62).
9. Install reverse shift rail into intermediate plate and position reverse arm bracket to intermediate plate (Fig. 63).
10. Install snap-ring onto reverse shift rail (Fig. 64).
11. Install reverse shift head and rail assembly into the intermediate plate.
12. Install fifth gear interlock ball and check ball (Fig. 65).
13. Install fifth gear shift rail (Fig. 66).
14. Remove intermediate plate from the vise, rotate plate 180° and reinstall plate in the vise using the same bolt and washer mounting set-up.
15. Install shift rail detent balls in the intermediate plate.
16. Install shift rail detent springs in the intermediate plate.
NOTE: Bottom detent spring is shorter than the others.
17. Install shift rail detent plugs in the intermediate plate.
18. Install 1-2 shift fork onto the 1-2 and 3-4 shift rails (Fig. 67).
19. Install snap-ring onto the 1-2 shift rail.
20. Install 3-4 shift fork onto the 3-4 shift rail (Fig. 68).
21. Install mainshaft into intermediate plate. Guide output shaft through opening in intermediate plate until the shift forks are aligned with the appropriate synchronizer sleeves. The mainshaft rear bearing will be started in the intermediate plate but not fully driven in at this point.
22. While an assistant supports the mainshaft, align rear of countershaft with inner race of countershaft rear bearing.
23. Raise countershaft upward until gears mesh with the mating gears on the mainshaft.
24. With a rubber mallet, tap on the input shaft and the front of the countershaft equally to install mainshaft rear bearing into intermediate plate and the rear of the countershaft into the rear countershaft bearing. It necessary hold countershaft into the intermediate plate and tap the countershaft rear bearing onto the countershaft and into the intermediate plate.
25. Install snap-rings onto the rear mainshaft and countershaft bearings.
26. Install bolts to hold the reverse shift arm bracket to the intermediate plate.
27. Install new bolts to hold the shift forks to the shift rails (Fig. 69).
28. Position mainshaft rear bearing retainer over the output shaft and onto the intermediate plate.
29. Install new bearing retainer bolts into the intermediate plate.
30. Move reverse shift arm into the reverse gear position. The reverse gear position is with the arm moved away from the intermediate plate (Fig. 70).
31. Install reverse idler gear assembly into position on the mainshaft and reverse shift arm.
32. Install compression spring and pin into the reverse idler gear shaft (Fig. 71).
33. Install reverse idler shaft through the intermediate plate and reverse idler gear assembly (Fig. 72) until idler shaft pin contacts the gear assembly.
NOTE: The notched cut-out in the idler shaft goes toward the rear of the transmission.
34. Align pin with the alignment notch in the reverse idler gear assembly (Fig. 73). Alignment notch in the reverse idler gear race/hub is a small relief cut above one of the main longitudinal slots. Verify pin is aligned with proper slot.
NOTE: The opposite slot has an oil drain hole which the pin could drop into. If this happens the assembly will then be locked onto the shaft and will need to be disassembled in order to be removed.
35. Depress compression spring and pin in reverse idler gear shaft (Fig. 74).
36. Install reverse idler gear shaft the remainder of the way through the reverse idler gear assembly.
37. Position reverse idler gear shaft lock plate onto the intermediate plate.
38. Install a new bolt to hold the idler gear shaft lock plate to the intermediate plate.
39. Install fifth gear thrust ring lock ball to the countershaft (Fig. 75).
40. Install fifth gear thrust ring onto the countershaft and over the lock ball (Fig. 76).
41. Install fifth gear shift fork to the countershaft fifth gear assembly.
42. Install countershaft fifth gear bearings into the countershaft fifth gear assembly.
43. Position countershaft fifth gear assembly on the countershaft. Verify fifth gear fork is installed onto the fifth gear shift rail.
44. Install fifth gear synchro ring.
45. Position fifth gear blocker ring onto the countershaft.
46. With a mallet and spacer, tap fifth gear blocker ring onto the countershaft.
47. Install new bolt to hold fifth gear shift fork to the fifth gear shift rail (Fig. 77).
48. Measure countershaft fifth gear thrust clearance.
49. Select a snap-ring that will provide a thrust clearance of 0.10 - 0.30 mm (0.004 - 0.010 in.).
50. Install snap-ring to hold fifth gear blocker ring onto countershaft.
51. Remove intermediate plate from vise and remove bolts and washers from intermediate.
EXTENSION AND ADAPTER HOUSING
1. Remove any residual sealer from transmission case, intermediate plate, and adaptertension housing.
2. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket T131281) Make sure to keep sealer bead to inside of bolt holes (Fig. 78).
3. Align geartrain and shift rails with mating holes in transmission case. Install transmission case to the intermediate plate (Fig. 79). Verify transmission case is seated on the intermediate plate locating pins.
4. Install new front bearing snap rings (Fig. 80).
5. Install front bearing retainer gasket to front bearing retainer.
6. Install front bearing retainer (Fig. 81) and tighten bolts to 17 Nm (15 ft. lbs.).
7. On 4x2 transmissions, install speedometer drive gear locating snap-ring (Fig. 82). Install speedometer gear lock ball in output shaft and install speedometer gear onto output shaft. Install speedometer gear retaining snap-ring onto output shaft.
8. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket TB1281 or equivalent, to sealing surface of adaptertension housing. Keep sealer bead to inside of bolt holes.
9. Install adapter or extension housing on intermediate plate (Fig. 83). Tighten housing bolts to 34 Nm (25 ft. lbs.).
10. Position shift arm in shifter tower opening of adapter or extension housing (Fig. 84). Verify shifter arm is engaged into the shift rails.
11. Start shifter arm shaft in hole in back of adapter or extension housing. Align shift arm and shifter arm shaft. Insert shifter arm shaft through the shifter arm and into forward portion of the adapter or extension housing (Fig. 85).
12. Rotate shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft.
13. Install shift arm retainer bolt and tighten to 38 Nm (28 ft. lbs.) (Fig. 86).
14. Install and tighten shifter arm shaft plug to 18 Nm (15 ft. lbs.) (Fig. 87).
15. Install shift restrictor pins in shift tower and tighten to 27 Nm (20 ft. lbs.) (Fig. 88).
CAUTION: Restrictor pins are not interchangeable and are color coded. Verify pins are installed in the original locations.
16. Install shift detent ball in detent opening of case (Fig. 89).
17. Install detent spring in case (Fig. 90).
18. Install detent plug and tighten to 19 Nm (15 ft. lbs.) (Fig. 91).
19. Install shift tower gasket onto shift tower.
20. Install shift tower oil deflector and gasket onto the adapter or extension housing.
21. Install shift tower onto transmission case (Fig. 92).
22. Install shift tower bolts and tighten to 18 Nm (15 ft. lbs.).
23. Install new metal O-ring onto the backup lamp switch.
24. Install backup lamp switch (Fig. 93) and tighten to 44 Nm (32.5 ft. lbs.).
25. Install new seal in adaptertension housing.
26. Install vehicle speed sensor, if necessary.
27. Install clutch housing, release bearing, release fork and retainer clip.