Transmission Reassembly
NOTE:
Apply recommended lubricant to each part before installing. Install NEW snap rings. DO NOT
reuse old snap rings.
- Install 2nd gear bearing, gear, spring, synchronizer ring, low-speed synchronizer hub and sleeve onto mainshaft. Ensure synchronizer sleeve is properly installed and keys fit snugly in slots. Using a hydraulic press and Bearing Installer (09925-18010), install low gear bushing.
- Install low gear needle bearing, spring, synchronizer ring, low gear ball and washer on mainshaft. Ensure ball fits into hole and slot in washer is positioned over ball. Using bearing installer, place center bearing onto mainshaft with ring groove facing up. See Fig 1.
- Install ball and washer with chamfered side facing center bearing. Ensure slot in washer is over ball. Preventing ball from falling out, press reverse gear bushing on shaft, using bearing installer. Install reverse gear bearing, reverse gear, reverse synchronizer hub and sleeve.
- Ensure hub is installed so smaller diameter and longer boss is toward mainshaft rear bearing. Sleeve should be installed so stepped side is toward mainshaft rear bearing. See Fig 2.
- Install reverse hub snap ring. Install 5th gear bearing, synchronizer ring and gear. Install ball and washer, ensuring oil groove faces 5th gear. Using bearing installer, press rear bearing onto mainshaft. Install snap ring. Install 3rd gear bearing and gear. Install synchronizer ring, hub and sleeve.
- Ensure hub is positioned so side with larger outer diameter boss is toward 3rd gear. Install synchronizer ring, needle bearing and input shaft. Drive countershaft front bearing into case. Using a plastic hammer, tap countershaft partially into front bearing.
- With countershaft in this position, using Bearing Installer (09925-18010), drive center bearing onto countershaft and into case. Install countershaft front snap ring. Install countershaft reverse gear and 5th gear on countershaft. Drive rear bearing onto countershaft. Install idler gear and washer onto reverse gear shaft. Install pin. Ensure pin and washer tongue are aligned.
- Install 3 locating springs into holes in upper case. Position locating balls on top of springs. Install low-speed gearshift shaft and low-speed shift fork in case. See Fig 3. Push down on locating ball and spring to allow shaft to pass through case.
- Install shift yoke pin. Install other shift shafts using the same procedure. Ensure shift forks are positioned correctly. See Fig 3. Install gear shift yokes on each shaft. See Fig 4. Ensure springs are positioned correctly. Ensure assemblies are positioned correctly.
- Install bearing stopper rings in both bearing saddles of lower case. Install alignment bushings in diagonal corners of lower case (if removed). See Fig 3. Install mainshaft and input shaft assembly in lower case. Apply Sealant (99000-31110) to mating surfaces of case halves. Position upper case half over lower case half. Align 3 shift forks with 3 grooves in synchronizer sleeve. Install case halves retaining bolts and torque to 13-21 ft. lbs. (18-28 N.m). Ensure shift shafts are in neutral position.
- Install shifter housing. Torque bolts to 13-21 ft. lbs. (18-28 N.m). Apply Loctite to reverse gear shift rim bolt threads. Install rim bolt and torque to 10-13 ft. lbs. (14-18 N.m). Apply grease to input shaft oil seal. Apply sealant to input shaft bearing retainer mating surface.
- Check operation of transmission by rotating input shaft by hand. Ensure transmission shifts into each gear easily and smoothly. Apply grease to release bearing inner surface. Install release bearing and springs. Install 2.75 pints (1.3L) SAE 80W-90 or SAE 75W-90 (recommended) gear oil in transmission and check for leakage. Recheck level with transmission installed in vehicle.