Assembly

ASSEMBLY
Transmission








Special Tool(s)

1. CAUTION: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure.

Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant.





2. Install the mainshaft assembly on the clutch housing.





3. Install the countershaft assembly.
Install the countershaft bearing cup. Do not install the shim at this time.





4. Install the output shaft on the countershaft. Install the output shaft bearing cup. Do not install the shim at this time.

5. NOTE: Clean the mating surfaces of the clutch housing and the transmission main case.

NOTE: Do not apply sealer at this time.

Install the transmission main case with four bolts in a cross pattern.





6. Check the countershaft endplay as follows:
1 Rotate the countershaft to seat the bearing.
2 Attach the special tool to the transmission case. Zero the dial indicator.
3 Holding the countershaft below the special tool, move the countershaft upward. Record the measurement.
^ Carry out this test three times.





7. Check the mainshaft endplay as follows:
1 Rotate the mainshaft to seat the bearing.
2 Attach the special tool to the transmission case. Zero the dial indicator.
3 Holding the mainshaft below the special tool, move the countershaft upward. Record the measurement.
1 Carry out this test three times.
8. Based on the recorded measurements, select the correct thickness shim. Remove the transmission main case. Install the shims. Reinstall the case.
^ Rotate the shafts to check if the shafts are tight.
^ Attach the special tool to the transmission case. Zero the dial indicator. Check that the endplay is within specifications. Re-adjust as necessary.
^ Remove the transmission main case.





9. Insert the reverse idler gear pin into the shift fork, and install the reverse idler gear. Position the fifth and reverse shift fork on the countershaft and the reverse idler gear, install the snap ring.








10. Install the first and second shift fork and the fifth and reverse shift rail.
1 Position the shift fork on the countershaft.
2 Install the shift rail with the notches facing the top of the clutch housing.
^ Make sure that the interlock pin does not obstruct entry of the shift rails.





11. Install the check ball, the detent spring and the shift rail detent plug.








12. WARNING: Make sure that the interlock pin is in position and does not obstruct entry of the shift rails.

Install the third and fourth shift fork and the third and fourth shift rail.
1 Position the shift fork on the countershaft.
2 Install the shift rail with the notches facing the top of the clutch housing.





13. Install the check ball, the detent spring and the shift rail detent plug.
^ Position the sift rail in the neutral position.





14. Install the first and second shift rail.
^ Position the shift fork on the shift rail.





15. Install the check ball, the detent spring and the shift rail detent plug.
^ Position the shift rail in the neutral position.





16. Install the countershaft shim. Use petroleum jelly to hold the shim in place.





17. Install the output shaft and the mainshaft shim. Use petroleum jelly to hold the shim in place.





18. Clean the mating surfaces of the clutch housing and the transmission main case. Apply silicone sealer to the clutch housing.





19. Install the transmission main case.





20. Install the five shift fork lock plates.
1 Install the O-rings on the shift fork lock plates.
2 Position the shift fork lock plates into the shift forks.





21. Install the five bolts.





22. Install the transmission main case to clutch housing bolts.





23. Install the reverse idler gear bolt.





24. Install the reverse lamp switch pin and the reverse lamp switch.





25. Install the shift rail ends.
1 Install the third and fourth shift rail end.
2 Install the first and second shift rail end.





26. Using a hammer, install new shift rail end roll pins.
Install the roll pin so that the split is parallel to the shift rail.





27. Install the fifth and reverse shift rail end, then install a new roll pin.





28. Install the detent spring seat, the detent springs and the shift rail detent plugs.





29. Install the fluid slinger ring, the output shaft gear, and the mainshaft fifth gear.





30. Install the special tool on the input shaft and to the clutch housing.





31. Install the output shaft and countershaft rear bearings.
1 Install the output shaft bearing and the countershaft rear bearing.
2 Install and tighten the output shaft locknut and the countershaft locknut to seat the bearing inner races.





32. Tighten the output shaft locknut and the countershaft rear locknut to specification.
^ Stake the nut in the groove on the shafts.





33. Assemble the extension housing.
1 Install the extension housing bearings.
2 Install the snap rings.





34. Using the special tools, install the output shaft seal.





35. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone sealer to the sealing surface of the extension housing, then install the extension housing.





36. Install the shift housing assembly.
Clean the mating surfaces of the extension housing and the shift housing. Apply a bead of silicone to the sealing surface of the shift housing.





37. Install the lower shift lever retainer.
38. Install the OSS sensor.
39. Install the clutch release lever and the clutch release hub and bearing.
40. Remove the transmission from the Holding Fixture.