GEARTRAIN Assembly
- Install Adapter 6747-1A on input shaft hub of Fixture 6747 (see Fig 1).
- Install input shaft in fixture tool. Make sure Adapter 6747-1A is positioned under shaft as shown (see Fig 2).
- Install pilot bearing in input shaft (see Fig 2).NOTE: The side of the pilot bearing with the small diameter goes toward the input shaft.
- Install fourth gear synchro ring on input shaft (see Fig 3).
- Adjust height of idler gear pedestal on assembly fixture (see Fig 4). Start with a basic height of 18.4 cm (7-1/4 in.). Final adjustment can be made after gear is positioned on pedestal.
- Install assembled output shaft and geartrain in input shaft (see Fig 5). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
- Install Adapter 6747-2B on front bearing hub of countershaft. The adapter has a shoulder on one side that goes towards the countershaft.
- Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears (see Fig 6).
- Check alignment of countershaft and output shaft gear teeth. Note that gears may not align perfectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This difference will not interfere with assembly.
- Position reverse idler in support cup of assembly fixture (see Fig 7). Ensure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary. Also be sure that short end of idler shaft is facing up as shown in illustration.
- On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (see Fig 8).
- Assemble 1-2 and fifth reverse-shift forks (see Fig 9). Arm of fifth-reverse fork goes through slot in 1-2 fork.
- Install assembled shift forks in synchro sleeves (see Fig 10). Verify forks are properly seated in sleeves.