Assemble

Synchromesh Mechanism:

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

Key Spring Installation:

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

2. Install synchronizer ring on 2nd gear, then slide 2nd gear on mainshaft with synchronizer ring toward rear of shaft.

Clutch Hub Assembly Direction:

3. Install 1st-2nd clutch hub and sleeve assembly on mainshaft with oil grooves on clutch hub toward front of mainshaft. Ensure 3 synchronizer keys engage notches in second synchronizer ring.
4. Press 2nd gear and 1st-2nd clutch hub and sleeve assembly into position using a suitable press adapter.
5. Slide 1st gear sleeve onto mainshaft, then assemble synchronizer ring and roller bearing to 3rd gear.
6. Slide 3rd gear onto mainshaft with synchronizer ring toward front of shaft.
7. Install 3rd-4th clutch hub and sleeve assembly on mainshaft in direction shown, using a suitable press and tool No. T77J-7025-B or equivalent. Ensure 3 synchronizer keys engage notches in synchronizer ring.
8. Install snap ring onto front of mainshaft, then slide on 1st gear bearing, synchronizer ring and 1st gear. Rotate 1st gear to engage 3 notches in synchronizer ring with synchronizer keys.
9. Slide thrust washer onto mainshaft, then install mainshaft and gear assembly into transmission case.
10. Position 1st-2nd and 3rd-4th shift forks in groove of clutch hub and sleeve assembly.
11. Slide synchronizer ring onto input shaft, then install input shaft to front end of mainshaft. Ensure 3 synchronizer keys in 3rd-4th synchromesh mechanism engage notches in synchronizer ring.
12. Install countershaft rear bearing inner race onto countershaft using a suitable press.
13. Install countershaft gear in case, ensuring countershaft gear engages each mainshaft gear.

Mainshaft Thrust Play Adjusting Shim:

14. Install correct shim on mainshaft center bearing, as selected.

Input Shaft & Mainshaft Center Installation:

15. Position input shaft bearing and mainshaft center bearing in their respective bores, ensuring synchronizer and shift forks have not been moved out of position. Press both bearings into place, until fully seated.
16. Install input shaft bearing snap ring and ensure tree operation of both synchronizers.

Placing Shim In Countershaft Front Bearing Bore:

17. Install correct shim in countershaft front bearing bore, as selected.

Countershaft Front Bearing Installation:

18. Position countershaft front and center bearings in bores and install tools as shown. Turn forcing screw until bearing is fully seated, then install front bearing snap ring.
19. Install bearing cover and torque attaching bolts to 41-59 ft lbs (55-79 Nm).
20. Install reverse idler gear and shaft with a spacer on each side of shaft.
21. Slide counter reverse gear, with chamfered side forward, and spacer onto countershaft.
22. Install thrust washer, reverse gear, caged roller bearings and clutch hub assembly onto mainshaft.
23. Install and hand tighten a new mainshaft locknut.

Removing Or Installing Locknut:

24. Shift transmission into 2nd and reverse gears to lock mainshaft, then torque locknut to 115-172 ft lbs (155-232 Nm), and stake locknut into mainshaft keyway.
25. Install 3rd-4th clutch sleeve in 3rd gear using synchronizer ring holder and spacer (tool No. T77J-7025-C or equivalent).

Checking Synchronizer Key Clearance:

26. If new synchronizers have been installed, measure clearance between synchronizer key and exposed edge of synchronizer ring using a suitable feeler gauge. If clearance is greater than 0.079 inch, change thrust washer between mainshaft center bearing and 1st gear, then recheck. If clearance is now within specifications, bend tab of lockwasher.

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

27. Install synchronizer ring on 5th gear, then slide 5th gear onto mainshaft with synchronizer ring toward front of shaft. Rotate 5th gear to engage 3 notches in synchronizer ring with keys in reverse clutch and hub.
28. Install thrust washer and lock ball onto rear of 5th gear and secure thrust washer with snap ring.

Checking 5th Gear Clearance:

29. Measure clearance between 5th gear thrust washer and snap ring. Clearance should be 0.0039-0.0118 inch and can be adjusted as necessary by selecting and installing the proper size thrust washer.

NOTE: Thrust washers are available in the following thickness: 0.2362, 0.2441, 0.2520, 0.2559, 0.2598, 0.2638, 0.2677, 0.2756 and 0.2835 inch.

30. Slide 1st-2nd shift fork shaft into transmission case, then connect shift fork to shaft using a new roll pin and install interlock pin.
31. Shift synchronizer hub into 5th gear, then position 5th-reverse shift fork on clutch hub. Slide shift fork shaft into case and connect fork to shaft using a new roll pin.
32. Install 2 blind covers and gaskets, and torque attaching bolts to 23-34 ft lbs (31-46 Nm).
33. Install 3 detent balls, springs and cap bolts into transmission case.
34. Apply a thin coat of liquid gasket No. E2AZ-19562-A or equivalent to center housing and transmission case mating surfaces, then position center housing on case.
35. Align reverse idler gear shaft boss with center housing attaching bolt boss, then install idler shaft capscrew and torque to 41-59 ft lbs (55-79 Nm).
36. Install counter 5th gear onto countershaft.

Countershaft Rear Bearing Installation:

37. Press countershaft rear bearing onto countershaft.

Checking Countershaft Rear Bearing Clearance:

38. Install, then measure clearance between countershaft rear bearing thrust washer and snap ring. Clearance should be 0.0000-0.0059 inch and can be adjusted as necessary by selecting and installing the proper size thrust washer.

NOTE: Thrust washers are available in the following sizes: 0.0748, 0.0787, 0.0827 and 0.0866 inch.

Mainshaft Rear Bearing Installation:

39. Remove filler plugs, then press mainshaft rear bearing into place.

Checking Mainshaft Rear Bearing Clearance:

40. Install, then measure clearance between mainshaft rear bearing thrust washer and snap ring. Clearance should be 0.0000-0.0039 inch and can be adjusted as necessary by selecting and installing the proper size thrust washer.

NOTE: Thrust washers are available in the following sizes: 0.0787, 0.0846 and 0.0906 inch.

41. Apply a thin coat of liquid gasket No. E2AZ-19562-A or equivalent to bearing housing and center housing mating surfaces, then position housings together.
42. Install shift fork shaft ends onto shift fork shafts and secure with roll pins.
43. Install lock ball, speedometer drive gear and snap ring onto mainshaft.
44. Install control lever and rod in extension housing.
45. Apply a thin coat of liquid gasket No. E2AZ-19562-A or equivalent to bearing housing and extension housing mating surfaces. Position housings together with gearshift control lever end laid down to the left as far possible. Install attaching bolts and nuts and torque to 60-80 ft lbs (81-108 Nm).
46. Install speedometer driven gear assembly into extension housing and secure with attaching bolt.
47. Ensure proper operation of gearshift control lever, then install transmission case cover gasket, with drain plug at rear. Install 14 cover attaching bolts and torque to 23-34 ft lbs (31-46 Nm).
48. Install correct shim, as selected in the "Inspection", on second step of front cover.
49. Apply a thin coat of liquid gasket No. E2AZ-19562-A or equivalent to front cover mating surface, then install front cover and tighten the 4 bolts and studs.
50. Fill transmission with 3 pints of suitable lubricant, then install filler plug and torque to 18-29 ft lbs (24-39 Nm).