Shift Forks And MAINSHAFT

WARNING: This page is about a different variant/trim than selected.

Install new sector shaft O-ring and bushing.

Fig 1: Installing Sector O-Ring & Bushing
Courtesy of DAIMLERCHRYSLER CORP.
Install shift sector in case. Lubricate sector shaft with transmission fluid before installation.

Fig 2: Installing Shift Sector
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Install range lever, washer, and nut on sector shaft. Tighten range lever nut to 27-34 N.m (20-25 ft. lbs.) torque.

Fig 3: Installing Range Lever
Courtesy of DAIMLERCHRYSLER CORP.
Assemble and install range fork and hub. Be sure hub is properly seated in low range gear and engaged to the input gear.

Fig 4: Installing Range Fork & Sleeve Assembly

Courtesy of DAIMLERCHRYSLER CORP.

Align and insert range fork pin in shift sector slot.
Install assembled mainshaft Be sure shaft is seated in pilot bearing and input gear.

Fig 5: Installing Mainshaft Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Install new pads on mode fork if necessary.
Insert mode sleeve in mode fork mode fork. Be sure long side of sleeve is toward long end of shift rail.

Fig 6: Assembling Mode Fork & Sleeve
Courtesy of DAIMLERCHRYSLER CORP.
Install assembled mode fork and sleeve. Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub.

Fig 7: Installing Mode Fork & Sleeve
Courtesy of DAIMLERCHRYSLER CORP.
Rotate sector to NEUTRAL position.
Install new O-ring on detent plug.

Fig 8: Identifying Shift Detent Components
Courtesy of DAIMLERCHRYSLER CORP.
Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
Install detent plunger, spring and plug. See Fig 8.
Verify that plunger is properly engaged in sector.