Transmission Case and 6th Gear Assembly
Transmission Case and 6th Gear AssemblyComponent Identification: Transmission Case and 6th Gear Assembly
Apply transmission lubricant to all parts as they are assembled
Combine Step 1 thru 6
1. Get the 6th Clutch Hub
2. Insert the 3-Synchronizer Keys
3. Install the Retaining Ring
4. Insert the 3-Synchronizer Springs into the keys
5. Insert the 3-Steel Balls
(Hold 2-balls in position with the thumb and index finger of one hand and hold the 3rd ball in position with your other index finger)
6. Use the picture to align the clutch hub and sleeve so they are facing the correct direction
- Align the keys in the hub with the notches in the sleeve
- Press the balls to compress the springs
- Slide the sleeve over the hub
Combine Step 7 and 8
7. Install SST 49-N017-207 into the clutch housing
- Place the Steel Detent Ball into the 5th shift arm
- Hold the Steel Ball in position
8. Install the shift rod into the housing until it contacts SST 49-N017-207Shift Rod
- Turn the notch in the shift rod towards shift rod A
Combine Step 9 thru 13
9. Transmission Case
- Set the transmission to neutral (See "view from A" picture)
- Apply sealant around the housing
(The housing must be assembled in less than 15 minutes. If the sealant hardens, it will not provide a good seal)
10. Install the Pressure Spring and Steel Detent Ball into the case
- Install the transmission case onto the clutch housing. Use a pin punch to compress the ball and spring until it passes the end of the shift rod
- If the countershaft bearing gets hung up on the countershaft, use a screwdriver covered with a shop rag to adjust the bearings until the countershaft bearing is fitted to the countershaft
- After the countershaft bearing is seated, you may need to help the case to seat, by tapping with a soft faced hammer
- Warning: Do Not Move the Shift Rod after the case is installed. There are parts that are installed later that limit the travel of the shift rod. If you try to move the shift rod to test transmission shifting before the Extension Housing has been installed, the lever will overtravel. You will have to take the case off again (starting at Step #9) to reset the Neutral position
11. Install the new rear main shaft Snap-Ring
- You will have to push the Main Drive Gear to expose enough of the bearing groove for the Snap-Ring to fit
12. Install 2-new front Snap-Rings
- You will have to push the main shaft forward to expose enough of the bearing groove for the snap-rings to be installed
13. Install the transmission case bolts (nine-12mm)
- Torque the case bolts 24 to 35 Nm (18 to 26 ftlb)
- Install the Reverse Idler Shaft Bolt "A" and new gasket to the transmission case
- Torque both bolts "A" and "B" 24 to 33 Nm (18 to 24 ftlb)
14. Apply sealant to the threads of the bolt (17mm), then install the Bolt to the passenger side of the case
- Torque it 23 to 40Nm (17 to 29 ftlb)
15. Install the small Steel Detent Ball and the long Pressure Spring to the passenger side of the case
16. Apply sealant to the threads of the plug
- Install the Plug (T-30 Torx) to the passenger side of the transmission
- Torque it 13.8 to 23.5 Nm (122 to 208 inlb)
17. Install a new Oil Seal into the input shaft housing
18. Apply sealant to the mounting surface of the Front Cover
(The housing must be installed in less than 15 minutes. If the sealant hardens, it will not provide a good seal)
- Apply sealant to the threads of each bolt (seven- 12mm)
- Torque the bolts 11 to 21 Nm (105 to 190 inlb)
If you disassembled the bearing retainer, perform Step Optional Step 19 thru 21
19. Push Pin
- Start the new spring pin into the cover as pictured
- Insert the push pin with the notch as pictured
Optional Step
20. Insert the Pressure Spring into the Bearing Cover
Optional Step
21. Spring Pin
- Compress the spring in a vice using SST 49-N017-105
- Brace the bearing cover with something to prevent it from moving
- Drive the new Spring-Pin into the housing
22. Install the Interlock Sleeve
23. Install the Inner Shift Lever to the shift arm
- Brace the shaft (2x4" wood used in picture)
- Install a new Spring-Pin
24. Install the Bearing Cover bolts (four / T45 Torx)
- Torque them 12.5 to 23.5 Nm (113 to 208 inlb)
25. Install the index Pin for the thrust washer into the countershaft
- Rounded side down
26. Install the Thrust Washer
- The chamfered side faces the front of the transmission, the flat side faces towards you
27. Place the split Needle Bearing onto the countershaft
28. Install 6th Gear onto the needle bearing
29. Place the 6th Gear Synchronizer Ring onto 6th gear
30. Place the 6th Clutch Hub onto the countershaft
- Make sure the hub is facing the correct direction
- Install SST 49-N017-2A0 to the Clutch hub
- Install the 6th clutch hub
- Make sure the tabs on the synchronizer ring stay aligned with the grooves in the hub while pressing the hub into position
31. Get the Selective Snap-Ring for (6th Synchronizer Hub)
- Install the correct Snap-Ring removed during disassembly into its groove
- Measure the clearance between the snap ring and the groove
- Add the feeler gauge thickness to the Snap-Ring thickness
- Use the chart to select the correct snap ring so the clearance is standard
- Replace the Snap-Ring with a new one even if the old Snap-Ring is the correct size
- Remove the old Snap-Ring and install the new Snap-Ring
32. Install the Steel Detent Ball
33. Install the 6th Shift Fork onto the clutch hub
- Pass SST 49-N017-208 through the 6th shift fork into the shift rod and tighten it
- Use SST49-N017-208 to pull the shift rod through the shift fork
- Align the hole for the steel pin in the shift fork with the hole in the shift rod
34. Install the Steel Ball and Pressure Spring into the bottom of the transmission
35. Apply sealant to the Plug (T-30 Torx)
- Torque the plug 13.8 to 23.5 Nm (122 to 208 inlb)
36. Install a new Spring Pin to 6th shift fork
- The notch in the rod should point towards the other shift rod
37. Get the Plug (10mm Hex)
- Remove SST 49-N017-207
- Apply sealant to the threads of the plug
- Torque the plug 13.8 to 23.5 Nm (122 to 208 inlb)