Assemble

Clutch Assembly:

1. Assemble 1st-2nd, 3rd-4th and 5th-reverse clutch hub assemblies by installing keys in hub, positioning sleeve over hub and keys, and placing springs onto hub.

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

2. Install retaining ring in 5th-reverse assembly.
3. Install 3rd gear and synchronizer ring onto front of mainshaft.

3rd-4th Clutch Hub Assembly Installation:

Clutch Hub Assembly Position:

4. Press 3rd-4th clutch hub assembly onto mainshaft, in direction shown in second image.
5. Install snap ring on mainshaft.
6. Install 2nd gear and synchronizer ring onto rear of mainshaft.

1st-2nd Clutch Hub Assembly Installation:

7. Press 1st-2nd clutch hub assembly onto mainshaft, in direction shown in second image.
8. Install synchronizer ring, 1st gear with sleeve, and thrust washer onto mainshaft.
9. Install input shaft and bearing onto mainshaft.
10. 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.
11. Place selected shim on countershaft rear bearing and press into bearing housing using tool No. T77J-7025-B or equivalent.
12. Place selected shim on mainshaft bearing and press into bearing housing using tool No. T77J-7025-K or equivalent.
13. Press front bearing onto countershaft using tool No. T71P-7025-A or equivalent.
14. 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:

15. Hold mainshaft in position and press countershaft assembly into bearing housing.
16. Install bearing cover and reverse idler gear shaft onto bearing housing. Ensure cover is fully seated in idler gear shaft groove.
17. Install thrust washer, sleeve, caged needle bearing and reverse gear onto output shaft (mainshaft).
18. Install reverse gear onto countershaft with offset toward bearing housing.
19. Install keyed thrust washer with tab in bearing housing groove.
20. Install reverse idler gear with offset toward bearing housing.
21. Ensure reverse gears are properly meshed, then install spacer and snap ring on idler shaft.
22. install 5th-reverse clutch hub assembly on output shaft.

Mainshaft Locknut Removal & Installation:

23. Lock transmission in reverse and any forward gear, then install a new output shaft locknut and torque to 94-152 ft lbs (127-205 Nm). Bend up tab on locknut.
24. Install 5th-reverse synchronizer ring and gear on mainshaft, ensuring grooves in synchronizer rings are aligned with keys in hub.
25. Install sleeves and counter 5th gear on countershaft.
26. Install lock ball in output shaft.
27. install thrust washer and retaining ring on output shaft. Ensure slot in washer is aligned with lock ball in output shaft.
28. Install output shaft bearing using tool No. T75L-7025-Q or equivalent, then the thrust washer and retaining ring.
29. Install countershaft rear bearing using tool No. T75L-7025-Q or equivalent, then the thrust washer and retaining ring.
30. Place all synchronizers in neutral position, then install inner spring and detent ball in lower bore.

Shift Fork Rod Interlock Pin Installation:

31. Install 5th-reverse shift rail using tool No. T75L-7025-Q or equivalent, then slide interlock pin through upper bore.
32. Install 3rd-4th shift rail, then the interlock pin and 1st-2nd shift rail.

Shift Fork Roll Pin Installation:

33. Assemble 1st-2nd and 3rd-4th shift forks to sleeves, then align roll pin holes of each shift fork and install new roll pins.
34. Install detent balls, springs and spring cap screws.
35. Install snap rings on 1st-2nd and 3rd-4th shift rails, and the snap ring and washer on 5th-reverse shift rail.
36. Apply suitable sealer to transmission case and bearing housing mating surfaces, and position case on housing.
37. Position shift lever gates on shift rails and install new roll pins.
38. Install lock ball in output shaft and position speedometer drive gear over ball.
39. Install snap ring and grommet on end of output shaft.
40. Apply suitable sealer to extension housing and intermediate housing mating surfaces, then install extension housing with control lever laid down and as far to the left as possible. Torque attaching bolts to 6-9 ft lbs (8-12 Nm).

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

Input Shaft Front Bearing Installation Tools:

41. Position outer snap ring on input shaft front bearing, then install bearing using tools shown in image. Tighten nut on forcing screw until bearing outer snap ring is fully seated.
42. Install input shaft snap ring.

Front Cover Clearance Adjustment:

43. Measure clearance between bearing outer race and front cover. This 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.
44. Install new oil seal in front cover using tool No. T71P-7050-A or equivalent.
45. Install shim in front cover recess.
46. Apply transmission fluid to oil seal lip inside front cover, then install cover and tighten attaching bolts.
47. Connect control lever end to control lever and torque attaching bolt to 20-25 ft lbs (27-33 Nm).
48. Install back-up lamp and neutral sensing switches to extension housing and torque to 20-25 ft lbs (27-33 Nm).
49. Install gearshift lever retainer and gasket and torque attaching bolts to 20-27 ft lbs (27-36 Nm).
50. Install gearshift lever if previously removed.
51. Install release bearing and fork.