- Verify that all synchro sleeves are in Neutral position (centered on hub).
CAUTION:
The transmission synchros must all be in Neutral position for assembly. Otherwise the housings, shift forks and gears can be damaged during installation of the two housings.
- Install 3-4 shift fork in synchro sleeve (see Fig 1). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown in illustration.
- Slide the end of shift shaft with shaft detent notches through 3-4 shift fork.
- Assemble shift shaft shift lever and bushing (see Fig 2). Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.
- Install assembled lever and bushing on shift shaft (see Fig 3).
- Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (see Fig 4).
- Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (see Fig 5).
- Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing.
CAUTION:
Positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.
- Select correct new roll pin for shift shaft lever (see Fig 6). Shaft lever roll pin is approximately 22 mm (7/8 in.) long. Shift socket roll pin is approximately 33 mm (1-1/4 in.) long.
- Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (see Fig 7).
- Seat shaft lever roll pin with pin punch (see Fig 8).
CAUTION:
The shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.
- Verify that lock pin slot in lever bushing is positioned as shown (see Fig 8).
- Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (see Fig 9).
- Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket (see Fig 10).
- Verify that notches in shift fork arms are aligned. Realign arms if necessary.