Assembly

Assembly






1. Install the mainshaft assembly in the case.






2. Choose and install a new selective snap ring in front of the input shaft bearing. Select the thickest snap ring that wilt fit in the groove. Refer to Input Shaft Selective Snap Ring Chart in the Specifications portion of this Section for the available sizes and identification colors.






3. Install the small caged needle bearing inside the input gear. Install the synchronizer ring on the input shaft. Check the clearance between the ring and gear. If the clearance is less than O.23mm (0.009 inch), replace the ring and/or input shaft.






4. Install the synchronizer ring and input shaft in the case. Rotate the input shaft so the flats face the countershaft to provide installation clearance.

NOTE: It may be necessary to tap the input shaft into position with a brass hammer.






5. Install a new snap ring on the outer bearing race. The longer portion of the race must be installed in the case.






6. Slide the outer ball bearing on the mainshaft Press the bearing on the mainshaft and in the race using Tube, T85T-7025-A, Replacing Shaft Sleeve, T75L-7025-K and Shaft Collar T75L-7025-M or equivalent. When pressed in position, all gears and shafts must rotate freely.






7. Install the 3-4 shift fork into its synchronizer sleeve. The roll pin boss on the fork must face to the rear.






8. Install the countershaft into the case. It may be necessary to move the mainshaft to one side in order for the countershaft to be easily inserted.






9. Install the 1-2 shift fork. The roll pin boss must face toward the 3-4 shift fork.






10. If removed, drive a new seal into the input shaft front bearing retainer using Seal Installer, T85T- 7011-A and Driver Handle, T8OT-4000-W or equivalents.
11. Install the large snap ring that retains the input shaft bearing to the case.






12. Before installing the bearing retainer the final assembled clearance "C" must be determined using the following procedure:






a. Measure the distance" A" from the face of the transmission housing to the face of the bearing.






b. Measure the depth of the recess "B" in the bearing retainer
c. To determine the correct thickness add 0.2mm (0.008 in) to the dimension measured for "B" (This is allowance for gasket thickness).
d. Subtract the dimension measured for "A" from the dimension determined in Step c (this is the thickness of the shim required).

NOTE: With the shim and gasket installed, the allowable clearance is 0.0-0.1 mm (0.0-0.004 in).

e. Install the appropriate size selective shim in the front bearing retainer. Refer to the Input Shaft Front Bearing Retainer-to-Bearing Selective Shim Chart in the Specifications portion of this Section for the available shim sizes and identification colors.
13. Install the countershaft front outer bearing race and non-selective spacer. Install the countershaft rear outer bearing race.






14. Install a new gasket between the front bearing retainer and case. Position the retainer on the case (with selective shim installed). Install the four bolts and four studs and tighten to 30-41 N.m (22-30 ft-lb).
15. Check and adjust the countershaft end play as follows:






a. Place the transmission so the rear of the mainshaft and countershaft face upward. Install the countershaft rear selective spacer.
b. Force the countershaft downward so it bottoms against the front bearing retainer.






c. Place a straight edge across the rear countershaft selective spacer in the case.
d. Try to turn the spacer. If the spacer turns lightly, replace the spacer with the next larger size. Install a spacer so the clearance between the spacer and straight edge is O.0O-O.O5mm (0.000-0.002 inch). Refer to the Countershaft End Play Selective Spacer Chart for the available sizes and identification markings on the spacer. Install the correct size spacer over the countershaft rear bearing cup.






16. Install the rear bearing retainer on the case with the four 6mm allen-head bolts. Tighten to 15-21 N.m (11-16 ft-lbs).

NOTE: Be sure the spacer installed in the previous step does not fall out of place when installing the rear bearing retainer.

17. Position the reverse idler gear shaft on the case. Install the 6mm allen-head bolts to act as a pilot. Install Reverse Idler Gear Shaft Remover. T85T-7140-A (or equivalent) on the shaft and drive the assembly into place Tighten the bolts to 15-21 N.m (11-16 ft-lbs).






18. Install the two caged needle bearings, reverse idler gear and thrust washer on the idler shaft. The boss on the idler gear faces away from the transmission. Install the locknut and tighten to 20-58 N.m (15-42 ft-lbs). If required, advance the nut to the next castellation and install the cotter pin.

NOTE: If required, cut one end of the cotter pin when it is bent over to prevent interference with the counter-overdrive gear.






19. Install the spacers and counter-reverse gear on the countershaft.






20. Press the reverse year sleeve on the mainshaft using Tube, T85T-7025-A, Shaft Sleeve Replacer, T75L-7025-K, Shaft Collar, T75L-7025-M and Forcing Screw, T84T-7025-B.






21. Install the caged needle bearing, reverse gear and the reverse synchronizer ring on the mainshaft.






22. Assemble the overdrive-reverse synchronizer hub and sleeve as follows:
a. Install the hub in the sleeve. The recessed boss on the sleeve must face the front of the transmission. The large boss on the hub must face the front of the transmission.






b. When installing hub in the sleeve and the three keys, make sure that the single tooth between the two spaces will touch the key. Install the springs so the open ends do not face each other.






23. Install the overdrive-reverse synchronizer on the mainshaft. The recessed boss of the sleeve must face the front of the transmission. Check the clearance between the reverse gear and the synchronizer ring. If the clearance is less than O.23mm (0.009 inch), replace the ring and/ or reverse gear.






24. Press the sleeve of the overdrive gear on the mainshaft using Tube, T75L-7025-B, Shaft Sleeve Replacer, T75L-7025-K, Shaft Collar, T75L-7025-M and Overdrive Gear Bearing Replacer, T85T-7061-A.






25. Install the ring on the overdrive-reverse synchronizer.
26. Slide the small spacer, caged needle bearing and overdrive gear on the mainshaft. Check the clearance between the overdrive gear and synchronizer ring. If the clearance is less than O.23mm (0.009 inch), replace the ring and/or overdrive gear.






27. Install the counter-overdrive gear and ball bearing onto the countershaft along with the 1-2 shift rail. Seat the bearing into position using Countershaft Bearing Replacer Collet, T85T-7121-A, Rear Countershaft Bearing Installer Adapter, TB5T-7111-A, and Remover and Replacer Tube, T77J-7025-B. Make sure the rail engages the forks.
28. Install the lock ball and spacer on the mainshaft.






29. Place the rear bearing over the mainshaft and press the bearing in position using Rack Bushing Holder, T81 P-3504-D (or an appropriate size washer), Tube T75L-7025B, Shaft Sleeve Replacer, T75L7025-K and Shaft Collar, T75L-7O25-M.






30. Install new locknuts on the countershaft and mainshaft. Double engage the transmission in two gears to prevent the shafts from turning. Tighten the mainshaft locknut to 245-265 N.m (180-195 ft-lbs) using Mainshaft Locknut Wrench, T77J-7025-C or equivalent. Tighten the countershaft locknut to 157-186 N.m (115- 137 ft-lbs) using a 3Omm socket. Disengage the transmission.
31. Stake the locknuts on the mainshaft and countershaft using Locknut Staking Tool, T77J-7025-F or equivalent.
32. Install mainshaft oil seal sleeve with a suitable tool, to dimension shown. Install with the outer chamfered edge toward the rear.

CAUTION: Do not scratch the outer (sealing) surface of the sleeve.






33. Install the interlock plunger in the bore between the 1-2 and 3-4 shift rails. Reposition the 1-2 shift rail so the flats for the poppet ball and spring and the interlock plunger are in the correct position. Make sure the roll pin holes for the shift forks are in alignment.






34. Install the overdrive-reverse shift fork on the synchronizer sleeve. Slide the 3-4 shift rail through the overdrive-reverse shift fork into the case and into the 3-4 shift fork inside the case. Position the shift rail flats to accept the poppet balls and interlock plunger. Insert the interlock plunger in the bore between the 3-4 shift rail and overdrive-reverse shift rail. Make sure the roll pin holes in the fork are in alignment.






35. Insert the overdrive-reverse shift rail so it engages the forks in the case. Make sure the roll pin holes in the fork and rail are in alignment.






36. Insert the poppet ball and spring in the overdrive-reverse (upper) bore in the case. The small end of the spring should be installed towards the ball. Install the set screw and tighten until the set screw head is 6mm (0.24 inchbelow the top of the bore.
37. Insert a poppet spring and poppet ball in the 3-4 and 1-2 bore (side two bores in the case). The small end of the spring must face towards the ball. Install and tighten the bolts.
38. Install the roll pins in the 1-2 and 3-4 shift forks.






39. Install the shift gates on the appropriate shift rails. Move the 1-2 gate and 3-4 gate to the rear of the rail.






40. Position a new gasket between the transmission case and the transfer case adapter. Make sure the selector arm is out of the gates and the change shifter is at the rear of the adapter. Position the adapter on the case making sure the shift gates clear the adapter. Make sure the shift rails and rear bearings line up with the bores in the adapter.






41. Install the three sizes of bolts (35mm, 55mm and 11Omm) in the appropriate holes in the adapter. Tighten the bolts to 15-21 N.m (11-16 ft-lbs).






42. Lubricate the inside diameter of the oil seal and position the seal around the output shaft, into the transfer case adapter. Press the seal in to place.






43. Install the neutral return plungers, springs and bolts in the adapter. The longer plunger with the slot for the detent ball is installed on the right side of the adapter.






44. Position the shift gates so the roll pin holes in the gates and rails are in alignment. Install the roll pins through the access holes. Install the access hole plugs.






45. Position the bottom cover and new gasket on the case. Install the bolts and tighten to 15-21 N.m (11-16 ft-lbs). DO NOT OVERTIGHTEN. Install the drain plug and tighten to 35-44 N.m (25-32 ft-lbs).
46. Insert the plunger detent ball and spring in the hole above the neutral return plunger in the adapter case.
47. Make sure the reverse lockout assembly on the control housing moves smoothly. Position a new seal on the adapter and install the control housing assembly. Install and tighten the bolts to 15-21 N.m (11-16 ft-lbs).






48. Install the backup lamp switch in the adapter.
49. Remove the fill plug and fill the transmission to the bottom of the fill hole with Standard Transmission Lube (SAE 80W) D8DZ-19C547-A (ESP-M2C83-C) or equivalent. The fluid capacity is 2.3 liters (4.8 U.S. pints or 2.0 Imperial quarts). Install the fill plug and tighten to 30-34 N m (22-25 ft-lbs).
50. Position the clutch slave cylinder on the input shaft. Position the clutch housing on the transmission case and install and tighten the nuts.