Assemble

Clutch Assembly:

1. Assemble 1st-2nd and 3rd-4th clutch hub assemblies by installing clutch hub and synchronizer into sleeve, positioning 3 keys into clutch hub slots, and placing springs onto hub.

NOTE: Open end of springs must be inserted into hub holes in direction shown in pervious image, to maintain equal spring tension on each key.

2. Install 3rd gear and synchronizer ring onto front of mainshaft.

3rd-4th Clutch Hub Assembly Installation:

Clutch Hub Assembly Position:

3. Press 3rd-4th clutch hub assembly on to mainshaft.
4. Install snap ring on mainshaft.
5. Install 2nd gear and synchronizer ring onto rear of mainshaft.

1st-2nd Clutch Hub Assembly Installation:

6. Press 1st-2nd clutch hub assembly onto mainshaft.
7. Install synchronizer ring, 1st gear with sleeve and thrust washer onto mainshaft.
8. Install input shaft and bearing onto mainshaft.
9. Measure countershaft rear bearing and mainshaft bearing clearances as follows:

Measuring Countershaft Rear Bearing Clearance:

Measuring Mainshaft Bearing Clearance:

a. Measure bearing bore depth "A" using a suitable depth micrometer.
b. Measure bearing height "B".
c. The difference between measurements "A" and "B" should be less than 0.0039 inch.
d. Select shims needed to bring bearing clearances within specifications. Shims are available in thickness of 0.0039 and 0.0118 inch.
10. Place selected shim on countershaft rear bearing and press into bearing housing using tool No. T77J-7025-B or equivalent.
11. Place selected shim on mainshaft bearing and press into bearing housing using tool No. T77J-7025-K or equivalent.
12. Press front bearing onto countershaft using tool No. T71 P-7025-A or equivalent.
13. Position countershaft and mainshaft assemblies on bearing housing with gears meshed.

NOTE: Ensure mainshaft thrust washer is installed at rear of 1st gear.

Countershaft Assembly Installation:

14. Hold mainshaft in position and press countershaft assembly into bearing housing.
15. Install bearing cover and reverse idler gear shaft onto bearing housing. Ensure cover is fully seated in idler gear shaft groove.
16. Install mainshaft reverse gear with key, then install and hand tighten mainshaft locknut.
17. Install countershaft reverse gear and snap ring, then lock transmission in any 2 gears.

NOTE: Mainshaft and countershaft reverse gears must be installed with chamfer on gear teeth facing rearward.

18. Install short spring and ball into bearing housing reverse bore. Hold ball down with a suitable tool and install reverse shift rod and shift lever assembly with reverse idle gear.

Shift Fork Interlock Pin Installation:

19. Install shift fork rods and interlock pins.

Shift Fork Pin Installation:

20. Assemble shift forks to clutch sleeves, then align roll pin holes of each shift fork and rod and install new roll pins as shown.
21. Install balls, springs and spring cap screws.
22. Apply suitable sealer to both bearing housing mating surfaces, then temporarily install housing to transmission case using 1 upper and 2 lower bolts only. Tighten attaching bolts to position countershaft front bearing in bore.

NOTE: It may be necessary to remove plugs from bell housing shift rod bores to align shift rods. When reinstalling plugs, a suitable silicone sealer must be used.

23. Torque mainshaft locknut to 116-174 ft lbs (156-235 Nm), then bend up a tab on lockwasher.
24. On models equipped with speed control, install speedometer drive gear and speed sensor.
25. On models less speed control, install speedometer drive gear, lock bail and snap ring.

Input Shaft Front Bearing Installation Tools:

26. Position outer snap ring on mainshaft, then install input shaft front bearing using tools shown in image. Tighten nut on forcing screw until bearing outer snap ring is fully seated against housing.
27. Install input shaft snap ring.
28. Attach speedometer driven gear assembly to extension housing with bolt and lock nut.
29. Install shift control lever through openings in front of extension housing.
30. Connect control lever end to control lever and torque attaching bolt to 20-25 ft lbs (27-33 Nm).
31. Install back-up lamp and neutral sensing switches to extension housing and torque to 20-25 ft lbs (27-33 Nm).
32. Remove 4 bolts which were temporarily installed to hold bearing housing in place.
33. Apply suitable sealer to bearing housing and extension housing mating surfaces, then install extension housing with control lever laid down and as far to the left as possible. Torque attaching bolts to 41-59 ft lbs (55-79 Nm) and ensure proper operation of control rod.
34. Install gearshift lever retainer and gasket and torque attaching bolts to 41-59 ft lbs (55-79 Nm).
35. Install gearshift lever, if previously removed.
36. Install new oil seal in front cover using tool No. T71P-7050-A or equivalent.
37. Apply transmission fluid to oil seal lip inside front cover, then install cover and torque attaching bolts to 41-59 ft lbs (55-79 Nm).

Front Cover Clearance Adjustment:

38. Measure clearance between bearing outer race and front cover. Clearance must be less than 0.004 inch and can be adjusted by adding a shim of 0.006 or 0.012 inch as needed.
39. Install release bearing and fork.