Shift Shaft Assemblies and Gear Cluster Install
- Lubricate all components as assembly progresses, using J 36850 transjel® lubricant.
Install the input shaft (1) in the clutch housing.
- Ensure the tabs on the blocking ring align with the corresponding pockets in the synchronizer hub. Click video link above for reference.
- Ensure the rings are assembled concentric to the centerline of the input shaft, this will aid in the output shaft installation into the pocket of the input shaft.
- Install the 4th gear blocking assembly:
- Install the 4th speed drive gear inner cone (4).
- Install the 4th speed drive gear outer cone (3).
- Install the 4th speed drive gear blocking ring (2).
- NOTE:
In order for the shift forks to properly line up with the synchronizers, the shift shaft assembly must be assembled correctly. Refer to Shift Shaft and Fork Assemblies Assemble (MM6) .
Assemble the shift shaft to the mainshaft.
- Install the mainshaft and the shift shaft assembly into the clutch housing.
- NOTE:
There is a keyway feature on the tip of the countergear that aligns with the pump. Ensure the counter gear seats onto the bar of the pump.
Install the counter gear assembly (1).
Install the Shift Shaft Assemblies (1 & 2).
Install the transmission case (1).
Install the clutch housing bolts (1) temporarily.
Install the interlock pins (1) into their groove in the case. Install the interlock pin (2) into the shift shaft where it meets the case.
Install the 4th gear assembly (1) using the DT-51076 bearing and gear installer (2).
Install the 3rd and 4th shift shaft (1). Ensure the interlock pin is installed in the shift shaft after shaft installation.
Install the shift shaft detent (3) and the shift shaft detent spring (2).
- Apply thread sealant to the detent spring cover bolt (1). Adhesives, Fluids, Lubricants, and Sealers (M13)
- TIghten the detent spring cover bolt (1) to 28 N.m (21 lb ft).
Install the shift control spacer (6)
- Install the shift bar support (interlock) (2) and selector finger and cam (5) at the same time.
- Install the shift interlock plate retainer bolts (1), shift control spacer (3), and neutral cam (4). Tighten the shift interlock plate retainer bolts to 31 N.m (23 lb ft).
- Using a 3/16 in drift punch and hammer drive the coiled spring pins downward and Install.
Install the reverse shift shaft assembly and manual transmission reverse selector lever (1) as an assembly.
Install the manual transmission 3rd & 4th selector lever (1), manual transmission 5th & 6th selector lever (2), and the manual transmission 1st & 2nd selector lever (3).
Using a 3/16 in drift punch and hammer drive the coiled spring pin (1) downward and Install.
Install the shift shaft detent spring cover bolt (1 and 6), shift shaft detent springs (2 and 5) and shift shaft detents (3 and 4).
- Apply thread sealant to the detent spring cover bolt (1). Adhesives, Fluids, Lubricants, and Sealers (M13)
Tighten shift shaft detent spring cover bolts to 28 N.m (21 lb ft).
- Using a 3/16 in drift punch and hammer drive the coiled spring pin downward and Install.
With the same drift in the shift rail, Install the shift shaft detent spring cover bolt (1), shift shaft detent spring (2), and shift shaft detent (3).
- Apply thread sealant to the detent spring cover bolt (1). Adhesives, Fluids, Lubricants, and Sealers (M13)
Tighten shift shaft detent spring cover bolt to 28 N.m (21 lb ft).
Using a 3/16 in drift punch and hammer drive the coiled spring pin downward and Install.
- Apply thread sealant to the detent spring cover bolt (1). Adhesives, Fluids, Lubricants, and Sealers (M13)
- Tighten the shift shaft detent spring cover bolt to 28 N.m (21 lb ft).
Install the 4th gear bearing assembly (2).
- Install the 3rd & 4th hub, 4th gear blocking rings, and 4th gear drive gear (1) as an assembly.
- NOTE:
The retaining ring must be installed as shown in graphic, with the points facing up.
Using snap ring pliers Install the retaining ring (3). Install the 3rd gear spacer (2).
- Install the 3rd & 4th synchronizer sleeve and fork assembly (1).
Using a 3/16 in drift and hammer, drive the coiled spring pin downward and Install.
Install the 3rd gear bearing assembly (4).
- Install the 3rd gear blocking ring assembly (1, 2, and 3).
- NOTE:
Thrust washer (1) must be installed with lip facing upwards as shown in picture.
Install the 3rd gear drive gear assembly (2) and the 3rd gear thrust washer (1).
Install the reverse drive gear assembly (4) using DT 25234 gear and bearing installer.
- Using snap ring pliers install the reverse drive gear assembly retainer (3).
- Install the counter gear rear bearing race (2) and snap ring (1).
Install the 3rd gear assembly (1) and the 3rd & 4th gear spacer (2) using DT-51076 bearing and gear installer.
Install the reverse gear bearing assembly (1) and bushing (2).
- NOTE:
- Ensure the tabs on the blocking ring align with the corresponding pockets in the synchronizer hub. Click video link above for reference.
- When the blocking ring is installed properly with the pockets lined up with the synchronizer hub, there should be NO gap between the blocking ring and the synchronizer hub assemble.
Install the reverse gear and synchronizer (5) together as an assembly, then install the reverse clutch gear (4). Using a suitable press tube and a rubber mallet, install the reverse gear and synchronizer assembly (5) and the reverse clutch gear (4) until fully seated.
- Install the spacer (1), main shaft rear bearing race (2), and the main shaft bearing spacer (3).
Using a 3/16 in drift punch and hammer drive the coiled spring pin downward and Install.
Ensure the tabs on the blocking ring align with the corresponding pockets in the synchronizer hub. Click video link above for reference.
Replacement bearings will be shipped as an assembly and only the race is installed at this point.
Replacement bearings will be shipped as an assembly and only the race is installed at this point.