Assemble

Synchronizer Mechanism:

1. Assemble 1st-2nd synchromesh mechanism by installing clutch hub to sleeve, placing 3 synchronizer keys into clutch hub keys slots and installing key springs to clutch hub.

Key Spring Installation:

2. When installing key springs, the open end of the spring should be kept 120° apart. This will keep the spring tension on each key uniform.
3. Assemble 3rd-4th synchromesh mechanisms in the same manner as step 1.
4. Place synchronizer ring on 3rd gear and slide 3rd gear to front of mainshaft with synchronizer ring toward front.

Clutch Hub Assembly Direction:

5. Slide 3rd-4th clutch hub and sleeve assembly to front of mainshaft, making sure that three synchronizer keys are engaged with notches in synchronizer ring. The direction of the 3rd-4th clutch hub and assembly should be as shown.
6. Install snap ring in front of mainshaft then place synchronizer ring on 2nd gear and slide second gear to mainshaft with synchronizer ring toward rear of shaft.
7. Slide 1st-2nd clutch hub and sleeve assembly to mainshaft with oil grooves of clutch hub toward front of mainshaft. Make sure that 3 synchronizer keys in synchromesh mechanism engage with notches in second synchronizer ring.
8. Insert 1st gear sleeve in mainshaft then press bushing in 1st gear using a suitable press adapter.
9. Place synchronizer ring on 1st gear and slide 1st gear onto mainshaft with ring facing front of shaft then rotate gear as necessary to engage 3 notches in ring with keys.
10. Install original thrust washer on mainshaft and position mainshaft and gears assembly in case.
11. Position caged bearing in front end of mainshaft.
12. Place synchronizer ring on 4th gear input shaft, and install input shaft to front end of mainshaft that 3 keys engage notches in ring.
13. Position 1st-2nd shift fork and 3rd-4th shift fork in groove of clutch hub and sleeve.
14. Using suitable press install inner race of countershaft rear bearing onto countershaft.
15. Position countershaft gear in case, making sure that gear engages each gear of mainshaft assembly.

Mainshaft Thrust Play Adjusting Shim:

16. Install correct shim in mainshaft rear bearing bore.
17. Position main drive gear bearing and mainshaft rear bearing into proper bearing bores. Be sure synchronizer and shifter forks have not been moved out of position.

Main Drive Gear & Mainshaft Rear Bearing Installation:

18. Press both main drive gear and rear mainshaft bearings into case using suitable press until both bearings are seated properly. Install main drive gear bearing snap ring.

Placing Shim In Countershaft Front Bearing Bore:

19. Place shim in countershaft front bearing bore.

Countershaft Front Bearing Installation:

20. Position countershaft front and rear bearings in bores and install suitable tools. Turn forcing screw until bearing is properly seated. Install snap ring to secure countershaft front bearing.
21. Install bearing retainer together with reverse idler gear shaft to transmission case. Tighten the four attaching bolts.
22. Slide counter reverse gear onto countershaft with chamfer to rear then install snap ring.
23. Install key on mainshaft.
24. Slide reverse gear and lockwasher onto mainshaft. Install new locknut and hand tighten.

Removing Or Installing Locknut:

25. Shift into 2nd gear and reverse gear to lock rotation of mainshaft. Torque locknut to 145-203 ft lbs (196-274 Nm).
26. Place 3rd-4th clutch sleeve in 3rd gear using tool No. T77J-7025-E.

Checking Synchronizer Key Clearance:

27. Check clearance between synchronizer key and exposed edge of synchronizer ring with feeler gauge. If measurement is greater than 0.079 inch, change thrust washer between mainshaft rear bearing and first gear. Check clearance again; if within specifications, bend tab of lockwasher.

NOTE: Thrust washers are available in the following thickness: 0.098, 0.138 and 0.118 inch.

28. From rear of case install 1st-2nd shift fork shaft assembly then install roll pin. Stake roll pin to secure shift fork to fork shaft.
29. Insert inter-lock pin into transmission.
30. From rear of case install 3rd-4th shift fork shaft assembly, then install roll pin and stake to secure shift fork to fork shaft. Place transmission in neutral.
31. Use the preceding two steps to install the reverse fork shaft assembly and reverse idler gear.
32. Position 3 detent balls and springs into case. Place copper washers on top 2 bolts and install 3 spring cap bolts, then install 2 blind covers and gaskets and torque the attaching bolts to 23-34 ft lbs (31-45 Nm).
33. Install lock ball, speedometer drive gear, and snap ring onto mainshaft.
34. Apply a thin coat of liquid gasket No. E2AZ-19562-A or equivalent to extension housing and transmission case mating surfaces.
35. Position extension housing with gear shift control lever end laid down to left as far as it will go, tighten the four attaching bolts.

NOTE: The 2 lower attaching bolts must be coated with a suitable locking compound prior to installation.

36. If removed, insert speedometer driven gear assembly to extension housing and secure it with bolt.
37. Check to ensure gearshift control lever operates properly.
38. Install transmission case cover gasket and cover with drain plug to rear. Install and torque the 14 attaching bolts to 23-34 ft lbs (31-45 Nm).
39. Position gasket and gearshift lever retainer to extension housing, and tighten the 4 attaching bolts.
40. Install shim on second step of clutch adapter plate, then coat adapter plate with liquid gasket No. E2AZ-19562-A or equivalent. Install adapter plate to transmission case and tighten the 4 attaching bolts and studs.

41. Remove filler plug and fill transmission with 3.0 pints of suitable lubricant. Reinstall plug and torque to 18-29 ft lbs (24-39 Nm).