Assembly

NOTE: Refer to while assembling and installing the shift rail components. Also, verify that all shift rail components are in their neutral position when installing the check balls and interlock pins.

1. Install the 3-4 shift rail into the intermediate plate.





2. Install the 1-2 elongated check ball into the intermediate plate.





3. Install the interlock pin into the 1-2 shift rail.
4. Install the 1-2 shift rail into the intermediate plate.
5. Install snap-ring onto 3-4 shift rail.





6. Install the 4th/reverse check ball into the intermediate plate.





7. Install the interlock pin into the 4th/reverse shift rail.





8. Assemble the reverse arm bracket to the reverse fork.





9. Install 4th/reverse shift rail into intermediate plate and position reverse arm bracket to intermediate plate.





10. Install snap-ring onto 4th/reverse shift rail.
11. Install reverse shift and rail assembly into the intermediate plate.





12. Install the fifth gear interlock ball and check ball.





13. Install fifth gear shift rail.
14. Remove the intermediate plate from the vise, rotate the plate 180�, and reinstall the plate in the vise using the same bolt and washer mounting set-up.
15. Install the shift rail detent balls in the intermediate plate.
16. Install the shift rail detent springs in the intermediate plate. Note that the bottom detent spring is shorter than the others.
17. Install the shift rail detent plugs in the intermediate plate.





18. Install the 1-2 shift fork onto the 1-2 and 3-4 shift rails.
19. Install the snap-ring onto the 1-2 shift rail.





20. Install the 3-4 shift fork onto the 3-4 shift rail.
21. Install mainshaft into the intermediate plate by guiding the output shaft through opening in intermediate plate until the shift forks are aligned with the appropriate synchronizer sleeves. The mainshaft rear bearing will be started in the intermediate plate but not fully driven in at this point.
22. While an assistant supports the mainshaft, align rear of countershaft with inner race of countershaft rear bearing.
23. Raise countershaft upward until gears mesh with the mating gears on the mainshaft.
24. Using a suitable rubber mallet, tap on the input shaft and the front of the countershaft equally to install the mainshaft rear bearing into the intermediate plate and the rear of the countershaft into the rear countershaft bearing. It may be necessary to occasionally hold the countershaft into the intermediate plate and tap the countershaft rear bearing onto the countershaft and into the intermediate plate.
25. Install snap-rings onto the rear mainshaft and countershaft bearings.
26. Install the bolts to hold the reverse shift arm bracket to the intermediate plate.





27. Install new bolts to hold the shift forks to the shift rails.
28. Position the mainshaft rear bearing retainer over the output shaft and onto the intermediate plate.
29. Install new bolts to hold the bearing retainer to the intermediate plate.
30. Install the reverse idler gear into position on the mainshaft and reverse fork.





31. Install the reverse idler shaft through the intermediate plate and reverse idler gear. Make sure that the notched cut-out in the idler shaft is to the rear of the transmission.
32. Position the reverse idler gear shaft lock plate onto the intermediate plate.
33. Install a new bolt to hold the idler gear shaft lock plate to the intermediate plate.





34. Install the fifth gear thrust ring lock ball to the countershaft.





35. Install the fifth gear thrust ring onto the countershaft and over the lock ball.
36. Install fifth gear shift fork to the countershaft fifth gear assembly.
37. Install the countershaft fifth gear bearings into the countershaft fifth gear assembly.
38. Position the countershaft fifth gear assembly on the countershaft. Ensure that the fifth gear fork is installed onto the fifth gear shift rail.
39. Install the fifth gear synchro ring.
40. Position the fifth gear blocker ring onto the countershaft.
41. Using a suitable mallet and spacer, tap the fifth gear blocker ring onto the countershaft.





42. Install new bolt to hold fifth gear shift fork to the fifth gear shift rail.
43. Measure countershaft fifth gear thrust clearance.
44. Select a snap-ring so that the thrust clearance is 0.10 - 0.30 mm (0.004 - 0.010 inch).
45. Install snap-ring to hold fifth gear blocker ring onto countershaft.
46. Remove intermediate plate from vise and remove bolts and washers from intermediate.