Assemble

Allow reverse idler shaft 0-ring to soak in transmission fluid for 10 minutes before installing.

1. Position countershaft in case.

2. Lubricate rear bearing and, using tool No. J 29895 and J-33032 or equivalent, install bearing so that it extends .125 inch (3 mm) beyond case surface. Support countershaft with two pieces � inch (7 mm) bar stock. Failure to support countershaft can result in permanent case distortion during bearing installation.

3. Install rear countershaft bearing race onto countershaft, then install countershaft retainer to transmission housing with bolts. This should be done temporarily with no shims installed. Torque retainer bolts to 15 ft. lbs.

4. Measure end play using dial indicator. Remove retainer and install necessary shim(s) between countershaft retainer and rear countershaft bearing race. Ensure end play is within 0.001-0.005 inch (0.0254 -0.127 mm). After installing countershaft retainer, bend tabs on retainer over four attaching bolts.

5. Position reverse idler gear in case with shift lever groove facing rear of case. Install reverse idler shaft from rear of case and position 0-ring between gear and shaft support. Install roll pin in shaft using a 3/16 inch (5 mm) pin punch.

6. If removed, apply pipe sealer with Teflon, or equivalent, to inhibitor spring anchor pin threads. Install anchor pin and torque to 6-11 ft. lbs.






7. Align 5th/reverse shift lever, reverse shift fork and inhibitor spring as shown. Lower assembly case and install looped end of inhibitor spring onto anchor pin.

8. Position reverse idler gear into Neutral position and align reverse shift fork onto reverse idler gear. Once aligned, push downward on shift fork until fully engaged into reverse gear. Note inhibitor spring rotation. Inhibitor spring should rotate counterclockwise into its installed position.

9. Install output shaft assembly.






10. Coat 15 input shaft roller bearings, thrust bearing and race with multipurpose grease, then install components in input shaft.






11. Align notches in blocking ring with inserts in 3rd/4th synchronizer and install blocking ring.






12. Install input shaft. Align flat on synchronizer teeth with countershaft before installing input shaft. Ensure 3rd/4th blocking ring is still in proper position.

13. Install bearing race in bearing retainer. Do not install end play shim at this point.






14. Temporarily install bearing retainer with narrow or smaller notch facing upward. Do not apply sealant to retainer at this point. Torque retaining bolt to 11-20 ft. lbs.






15. Install output shaft rear bearing race. Tap bearing race into position using a plastic tip hammer, if necessary.






16. Install 5th/reverse shift rail into transmission case by aligning ball stud with slot in case and aligning shift rail with reverse shift fork. Once ball stud enters case, rotate shift rail clockwise and push in shift rail until ball aligns with 5th/reverse shift lever. Rotate shift rail counterclockwise until ball stud fully engages shift lever.






17. Install 5th gear synchronizer and shift fork as an assembly, then 5th gear blocking ring, retainer and snap ring. Ensure tabs on retainer engage splines of countershaft.

18. Before installing pivot pin, ensure shift rail ball stud is fully engaged with shift lever. Apply pipe sealant with Teflon, or equivalent, to pivot pin threads and install 5th/reverse shift lever pivot pin. Torque pivot pin to 20 ft. lbs. using T50 Torx driver.

19. Apply pipe sealant with Teflon, or equivalent, to back-up lamp switch and install using a 22 mm socket. Torque back-up lamp switch to 20 ft. lbs.






20. Install C-clip on shift lever pivot pin using needle-nose pliers.

21. Install speedometer gear. Tab on retainer clip engages a hole in output shaft.

22. Apply a 1/8 inch bead of silicone rubber, or equivalent, to shift cover assembly. Do not apply silicone sealer to top of transmission case surface under any circumstances, as sealant could fall into transmission and affect operation. Position cover to filler plug side of transmission and lower into position until shift forks engage
synchronizers. Continue lowering cover and move into position to engage 5th/reverse shift lever. Ensure all synchronizers are in Neutral position and that shift forks in cover are in Neutral position.

23. Install shift cover retaining bolts. Torque retaining bolts to 6-11 ft. lbs.

24. Apply a 1/8 inch bead of silicone rubber, or equivalent, on extension housing mating surface and oiling funnel. Install funnel to extension housing.






25. Coat detent spring with petroleum jelly and install in offset lever. Lubricate detent plate and install detent ball in Neutral position on plate. Position offset lever in extension housing with spring over detent ball.

26. Slide lever and extension housing into position as an assembly. Ensure oiling funnel engages into 5th gear synchronizer.






27. Press downward on offset lever to compress detent spring and push lever and housing into position.

28. Install extension housing retaining bolts. Torque bolts to 30-45 ft. lbs.

29. Align hole in shifter shaft with hole in offset lever, then install roll pin with suitable pin punch. Install damper sleeve in offset lever.

30. Check output shaft geartrain end play as follows:

a. Rotate output shaft geartrain to vertical position with extension housing facing up.

b. Mount dial indicator on extension housing with indicator stylus contacting output shaft.






c. Rotate input and output shafts. Zero dial indicator.

d. Push upward on input shaft using a wood block, then note dial indicator reading. A shim must be installed that is the thickness of indicator reading; this will provide zero end play. Although zero end play is ideal, a plus or minus 0.002 inch is an acceptable tolerance. Do not overload bearings with too thick a shim.






31. Rotate transmission to horizontal position and remove front bearing retainer, then remove bearing race from retainer. Install necessary shim(s).

32. Apply a 1/8 bead of silicone rubber, or equivalent, to bearing retainer, then install bearing retainer with narrow or smaller notch facing upward. Torque retaining bolts to 11-20 ft. lbs. Sealer must not cover notch in bearing retainer.

33. Apply a 1/8 bead of silicone rubber, or equivalent, to shift cover.

34. Position shift cover on extension housing, then torque retaining bolts to 12-15ft. lbs.

35. Install and torque drain plug to 12-22 ft. lbs.