Assemble
1 of 2:
2 of 2:
1. Install short locking pin with round side first, long locking pin with round side first and ball shift into rail locking pin bore. Lightly coat pins and balls with grease to prevent them from falling out.
2. Press gearshift shaft ball sleeve into front case until fully seated.
3. Heat front case to 176°F, then press input shaft main bearing into front case using tool No. J 37341 or equivalent. Place roller bearing side first.
4. Install countershaft input bearing into front case using tool No. J 37339 or equivalent, until fully seated.
5. Install countershaft selective shim onto bearing, then install snap ring. Snap ring must be fully seated into front case groove with no axial movement of selective shim. If snap ring cannot be installed or there is slack between snap ring and selective shim, increase or decrease shim size, refer to chart for shim size availability chart.
6. Press dowel pins into front case.
7. Install complete gear set with 3M shift rail and shift fork assembly, then 1-2 shift fork and 5-6 shift rail and fork into tool Nos. J 37337-2 and J 37337-3 or equivalents.
8. Install front case with fixture plate tool No. J 3733-1 or equivalent, to output shaft and counter shaft assemblies. Do not install fixture bolts until 4th gear input shaft is fully seated into input shaft main bearing.
9. With 5-6 shift rail in 6th gear position, then press input shaft combination bearing onto input shaft.
10. Install snap ring. Snap ring is available in 0.092, 0.096 and 0.100 inch thicknesses. Install the thickest snap ring that will fully seat into output shaft.
11. Install 1-2 shift rail with detent notches toward rear, through 1-2 shift fork. Shift fork must be offset toward rear.
12. Install 1-2 shift fork and rail assembly, 1-2 synchronizer sleeve onto front case, then 1-2 shift rail and fork assembly roll pin and roll pin lock.
13. Install reverse shift fork with fork offset to rear, onto reverse synchronizer sleeve, then reverse shift rail with detent notches toward output, through reverse shift fork.
14. Install reverse shift fork roll pin and roll pin lock. Drive roll pin until 0.020 inch protrudes above shaft, then drive lock pin and roll pin together until fully installed.
15. Install 5-6 shift rail detent spring into front case, then 5-6 shift rail detent sealing cap onto detent bore. Install cap flush with case.
16. Install gearshift shaft into front case with solenoid detent facing away from gear sets.
17. Install front case gasket onto front case.
18. Install rear case to front case. Ensure gearshift shaft and seal is properly positioned. Do not force cases together, fit should be free and without binding.
19. Install rear case attaching bolts, then torque attaching bolts to 19 ft. lbs.
20. Press output shaft rear bearing onto output shaft. Ensure roller bearing side is facing forward. Inner ring of bearing must be heated to 176°F before installing onto output shaft.
21. Install selective shim, then snap ring. Snap ring must be fully seated into front case groove with no axial movement of selective shim. If snap ring cannot be installed or there is slack between snap ring and selective shim, increase or decrease shim size, refer to chart for shim size availability chart.
22. Install extension housing. Refer to Extension Housing & Speed Sensor Gear under Subassembly Service for procedure to measure output shaft end play.
23. Install reverse idler gear assembly.
24. Install reverse shift rail detent, detent spring, then plug into reverse detent bore in rear of case. Shortest detent spring is for reverse shift rail detent.
25. Install 3-4 shift rail detent, then detent spring into rear case.
25. Install 1-2 shift rail detent, detent spring, then plug into 1-2 detent bore in rear case.
27. Install 5-6 shift rail detent, detent spring, then plug into 5-6 detent bore on left side of front case.
28. Install gearshift shaft detent, detent outer spring, then detent inner spring into front case.
29. Install gearshift shaft detent plug into front case. Torque to 26 ft. lbs.
30. Using a suitable sealing compound, install front case sealing cap flush with case.
31. Install vent fitting, then vent tube. Torque to 11 ft. lbs.
32. Install back-up lamp pressure pin into bore, then back-up lamp switch into front case. Torque switch to 35 ft. lbs.
33. Install fill and drain plugs. Torque drain plug to 26 ft. lbs.
34. Rotate support assembly so input shaft is facing up, then install selective shim to front case. Measure selective as follows:
a. Measure from sealing surface of front case to input shaft bearing outer race.
b. Measure from input shaft bearing retainer flange gasket surface with new gasket in place, to retainer tube selective shim mating surface.
c. The distance from measurements in steps a and b, minus clearance needed to compress gasket, which is between 0.002-0.004 inch, is equal to thickness of selective shim. Refer shim availability chart.
35. Install bearing retainer and gasket, attaching bolts. Torque attaching bolts to 16 ft. lbs.
36. Remove tool No. J 38130 or equivalent from countershaft, shift transmission into 5th gear, then attach countershaft nut using tool No. J 38131 or equivalent while holding input shaft with tool No. J 38746 or equivalent. Torque Attaching nut to 162 ft. lbs.
37. Using a drift, peen upper edge of countershaft nut over into countershaft threads in two or more places.
38. Install countershaft seal into front case, using tool No. J 29381 or equivalent.