Assemble

NOTE: Lubricate components with transmission fluid prior to assembly.

1. Insert countershaft, small end first, into bore at rear of case. Slide shaft in just enough to position rear countershaft steel thrust washer on shaft and against case. Hold washer in place with a small amount of grease.
2. Insert small end of shaft into front countershaft bore just enough to hold steel thrust washer in position, then install the thrust washer. Use reverse idler shaft as a temporary holding tool.

NOTE: Ensure notch in thrust washers are aligned with boss at each end of case.

3. Position countershaft cluster gear assembly in case. Use care to avoid losing any rollers.
4. Slide out reverse idler shaft and countershaft gear dummy shaft by installing countershaft from rear. Maintain contact between shaft ends to avoid losing rollers. Do not drive countershaft completely into case at this time.
5. Install reverse idler gear assembly and idler shaft into case, ensuring shift fork groove is not toward front of case. Do not drive shaft completely into case at this time.
6. Ensure countershaft and reverse idler gear shaft are properly aligned, then drive shafts into position and install retainer and bolt.
7. Install output shaft assembly into case. Tilt assembly slightly to the right, then position reverse shifter arm and shoe assembly on reverse idler gear.
8. Install pivot screw through hole in left side of case and into shifter arm hole.
9. Install spring clip to secure shifter arm to pivot screw, then center output shaft assembly in case bore.
10. Slide input shaft through front bore, ensuring flats on shaft face upward. When past countershaft, rotate input shaft so flats face downward, then guide input shaft onto output shaft. Install input shaft oil baffle.
11. Install dummy bearing No. T75L-7025-Q or equivalent on transmission input shaft.
12. Install snap ring in groove in outer race of output shaft bearing.

Output Shaft Bearing Installation:

13. Install output shaft bearing. Install spacer washer against rear face of bearing, then position snap ring behind washer in output shaft. Remove dummy bearing from input shaft.

Input Shaft Bearing Installation:

14. Insert input shaft bearing and secure with thickest snap rings that will fit on bearing.
15. Install input shaft bearing thrust spacer, retainer gasket and retainer. Torque retainer attaching bolts to 15-25 ft lbs (20-33 Nm).
16. Install speedometer drive gear and spacer, if equipped, on output shaft over lock ball. Secure drive gear with snap ring.
17. Install output shaft bearing retainer, or extension housing, using a new gasket. Torque attaching bolts to 34-45 ft lbs (45-60 Nm).
18. Apply suitable lubricant to retainer, bushing, seal and U-joint flange, then install U-joint flange. Lock transmission in any two gears and torque retaining nut to 75-115 ft lbs (101-155 Nm).
19. Install gearshift housing, with housing and lever in 2nd gear, on transmission and torque attaching bolts to 25-35 ft lbs (33-47 Nm).
20. Fill transmission to proper level, then add an additional 1/2 pint of lubricant through speedometer cable hole in extension housing.