Assembly
PRECAUTION1. All O-rings and gaskets must be replaced with new ones included in the overhaul kit.
2. Verify that all parts are completely cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil.
4. After assembly, shift the transmission to each position, and check for smooth and correct operation.
PROCEDURE
A. Assemble in the order shown in the illustration, referring to the following notes:
Secondary Shaft Center Bearing Outer Race (4)
^ Use a brass drift to install the secondary shaft center bearing outer race.
NOTE: Make sure that the outer race is squarely positioned in the bore.
Primary Shaft (5)
1. Press the primary shaft bearing onto the primary shaft using Bearing Cone Remover T71P-4621-B, or equivalent and the SST.
2. Install the plastic scoop ring.
NOTE: Manually rotate the scoop ring clockwise to make sure that the main drive gear oil holes properly engage the scoop ring. A click should be heard as the scoop ring notches align with the primary shaft oil holes.
Center Bearing Cover (8)
^ Install the center bearing cover with the reference arrow pointing up. Tighten to 18 - 26 Nm (13 - 19 ft. lbs.).
NOTE: Make sure that all bolt heads are marked with an "8".
Countershaft Lever Assembly (16)
^ Install the countershaft lever assembly. Tighten to 8 - 10 Nm (72 - 84 ft. lbs.).
Front Bearing Cover (10)
1. If removed, install the front cover oil seal using the SST.
2. Measure height A of the primary shaft bearing outer race.
3. Measure depth B of the front cover outer race bore.
4. Measure depth C of the countershaft front bearing race.
5. Measure depth D of the front cover outer race bore.
6. Select an adjustment shim(s) to maintain end play within the specified limits.
^ B-A + adjustment shim = 0.05 - 0.15 mm (0.002 - 0.006 inch).
^ C+D - adjustment shim = 0.15 - 0.25 mm (0.006 - 0.010 inch).
7. Position the bearing shim and baffle plate into the front cover (install the shim with the groove showing).
8. Install the spacer in the transmission countershaft front bearing bore.
9. Tape the primary shaft splines along their entire length.
10. Apply a 1/8 inch bead of appropriate sealant to the front cover and bolt threads.
11. Install front cover. Tighten to 16 - 22 Nm (12 - 16 ft. lbs.).
NOTE: Make sure that the bolt heads are marked with a "6".
Shift Fork Assembly (21)
1. Install the spring and detent ball into the shift fork.
2. Depress the detent ball and insert the shift rail.
3. Locate the neutral position.
4. Install the 5th / reverse clutch hub and sleeve, and the 5th gear synchronizer ring on the shift fork assembly.
NOTE: The reference mark on the synchronizer sleeve must be installed toward the reverse gear side.
5. Install the shift fork assembly on the countershaft.
6. Apply sealant to the threads of shift fork assembly bolt and tighten to 20 - 30 Nm (16 - 22 ft. lbs.).
Split Washer (23)
1. Measure the countershaft reverse gear end play if the original split washers are not being installed.
2. If the end play is not within 0.25 - 0.35 mm (0.010 - 0.014 inch), select the proper split washer.
Thrust Washer (24)
1. While pushing the thrust washer against the shoulder on the countershaft, measure the clearance between the thrust washer and the countershaft reverse gear.
2. If the clearance is not within 0.25 - 0.35 mm (0.010 - 0.014 inch), select the proper thrust washer.
Reverse Idler Gear (29)
1. Install the thrust washer onto the reverse idler gear.
NOTE: Make sure the tabs on the thrust washer mates with the groove on the reverse idler shaft.
2. Install the needle bearings, idler gear, and spacer.
3. Install the original retaining ring.
4. Measure the end play between the retaining ring and the reverse idler gear.
5. If the end play is not within 0.1 - 0.2 mm (0.0039 - 0.0078 inch), select the proper retaining ring.
Countershaft Rear Bearing (34)
^ Temporarily install a suitable spacer (inner bore larger than 21 mm (0.82 inch), outer bore smaller than 36 mm (1.41 inch), 15 - 20 mm (0.59 - 0.78 inch) overall length) in place of the countershaft bearing.
Secondary Shaft Rear Bearing (33)
^ Install the secondary shaft rear bearing using the SST, Shaft Adapter T75L7025-M (4x4 only), Gear Installing Spacer T88T-7025-E, or equivalents.
Locknuts (35, 36)
CAUTION: Do not reuse the removed locknuts.
1. Remove the temporary spacer from the countershaft.
2. Install the countershaft rear bearing.
3. Lock the transmission into 1st and 3rd gears.
4. Install the secondary shaft locknut. Tighten to 216 - 274 Nm (159 - 202 ft. lbs.).
5. Install the countershaft locknut. Tighten to 128 - 196 Nm (94 - 144 ft. lbs.).
6. Stake the locknuts.
B. Install the oil passage and tighten to 8 - 10 Nm (72 - 84 inch lbs.).
C. Install the speedometer drive gear, referring to the following:
^ The speedometer drive gear contains detents into which the steel drive ball can be installed. The steel drive ball can be installed into any of the three detents.
D. Install the extension housing, referring to the following:
a. Install the extension housing. Tighten bolts to 32 - 46 Nm (24 - 33 ft. lbs.).
b. Install the extension housing rear oil seal using the Extension Housing Seal Replacer T61 L-7657-A, or equivalent.
NOTE:
^ Make sure that the oil seal drain hole faces downward.
^ The extension housing bushing cannot be serviced. If the bushing requires service, the extension housing must be replaced.
E. Install the control case, referring to the following:
^ Install the control case. Tighten to 16 - 22 Nm (12 - 16 ft. lbs.).
NOTE: Do not apply sealant to the control case or transmission mating surfaces.
F. Add the specified amount and type of transmission oil.
G. After assembly, shift the transmission to each position, and check for smooth and correct operation.