Assemble

NOTE: All bolts and plugs used in the reassembly of the transmission should be coated with a suitable sealant to prevent leakage.

Installing Reverse Idler Gear:

1. Position reverse idler gear with long end of hub facing toward rear of case. Install idler gear shaft into case and gear with roll pin holes aligned. Secure with roll pin.
2. Install countershaft and bearings into case, then the rear bearing cup and snap ring.
3. Install front bearing cup, shim, gasket and bearing retainer onto front of case and secure with cap screws. Torque cap screws to 7-10 ft lbs (9-13 Nm) while rotating gear. If rotating effort increases while tightening bearing retainer, replace shim with next size thicker. Correct endplay should be 0.001-0.005 in.
4. Install mainshaft into case, then lubricate two thrust washers and thrust bearing. Install one thrust washer onto 3rd-4th speed synchronizer thrust surface and thrust bearing and second thrust washer onto 3rd-4th speed synchronizer.

Input Shaft Replacement:

5. Install input shaft into case with blank portion of teeth facing toward countershaft gear.
6. Install new C-ring into bearing retainer groove and the output shaft rear bearing cup and snap ring onto rear of case.
7. Position shim and bearing retainer into case, then secure retainer to case with cap screws. Torque cap screws to 8-10 ft lbs (10-13 Nm). while rotating input shaft. If rotating effort increases while tightening bearing retainer, replace shim with next size thicker. Output shaft endplay should be 0.001-0.005 in.
8. Assemble spring and reverse fork onto relay lever, then install lever assembly into case and secure with pivot pin and C-clip.

Installing 5th Speed Cluster Gear:

9. Install 5th speed cluster gear, then the cluster gear snap ring.
10. Assemble 5th speed main drive gear onto mainshaft shaft, then lubricate blocker ring and assemble onto main drive gear.
11. Assemble 1st-2nd and 3rd-4th shift forks onto main shaft assembly.
12. Install interlock gear selector sleeve between the two shift forks, then the interlock pilot bolt into right side of case.

Removing Shift Shaft & 5th Speed Synchronizer:

13. Install shifter shaft, 5th speed shift fork and 5th speed synchronizer as an assembly.
14. Install gearshift selector pin into shifter shaft then the roll pin.
15. Install 5th speed synchronizer retaining drive and snap ring onto output shaft.
16. Install speedometer drive gear ball, drive gear and snap ring onto output shaft.
17. Install extension housing to case and torque retaining bolts to 40-60 ft lbs (54-81 Nm).
18. Install 5th gear pilot bolt into top of extension housing.
19. Shift transmission into reverse gear. Install offset lever and roll pin onto rear of shifter shaft.
20. Install detent plunger, spring and plug into upper right side of case and torque plug to 12-14 ft lbs (16-18 Nm).
21. Install extension housing access plug into rear of extension housing.
22. Install gasket and cover onto case and torque cover bolts to 8-10 ft lbs (10-13 Nm).