Assembly

Assembly





1. Install the countershaft cluster gear.





2. Position the primary shaft.





3. Install the secondary shaft.

Note:
- Make sure the fourth gear synchronizer blocking ring is in place.

4. Mate the primary shaft and secondary shaft together.





5. Install the countershaft pilot bearing.





6. Install the secondary shaft rear bearing.





7. Install the center bearing retainer and bolts.

Note:
- Install the rear bearing retainer with the arrow pointing to the top of the case.





8. Use Bell Housing Seal Replacer SST 49 UN01 012 to install the (A) front cover oil baffle.

Note:
- If any related parts (such as the secondary shaft and bearings) have been replaced, perform the shim thickness selective procedure.

9. Position the transmission with the bell housing facing up.





10. Use (B) Depth Micrometer to measure dimension (A) primary shaft bearing race depth.
1) Record dimension (A) on line 2 of the selective shim equation chart.





11. Use (A) Depth Micrometer to measure dimension (B) front bearing retainer depth.
1) Record dimension (B) on line 1 of the selective shim equation chart.








12. Select the proper secondary shaft shim.





13. Use (A) Depth Micrometer to measure dimension (C) countershaft bearing.
1) Record dimension (C) on line 1 of the countershaft spacer equation chart.





14. Use (A) Depth Micrometer to measure dimension (D) countershaft bearing retainer depth.
1) Record dimension (D) on line 2 of the countershaft spacer equation chart.








15. Select the proper countershaft spacer.





16. Position the (A) bearing shim, the (B) fluid baffle, and the (C) countershaft spacer onto the front bearing cover.

Note:
- If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.

17. Install the front bearing cover.
1) Position the front bearing cover.
2) Install the bolts.
Tightening Torque 16 - 22 Nm (1.6 - 2.2 kgf-m, 12 - 16 ft. lbs.)

Note:
- To prevent damage to the fluid seal lip during assembly, tape the primary shaft splines.





18. Position the oil trough bolt.
19. Install the oil trough bolt.
Tightening Torque 8 - 10 Nm (82 - 102 kgf-cm, 71 - 89 inch lbs.)





20. Install the secondary shaft fourth gear.





21. Install the (A) race and the (B) fifth speed gear split bearing on the countershaft.





22. Install the countershaft fifth gear speed.





23. Install the counter lever shaft assembly.
1) Position the counter lever shaft and plate.
2) Install the counter lever shaft bolt.





24. Install the 5th reverse shift lever.
1) Position the 5th reverse shift lever.
2) Install the 5th reverse shift snap ring.





25. Install the countershaft fifth gear synchronizer blocking ring.





26. Install the (A) fifth/reverse shift rail, the (B) shift fork, and the (C) synchronizer.

Note:
- The reference mark on the synchronizer sleeve must face toward the reverse gear.

27. Install the bolt.
Tightening Torque 20 - 30 Nm (2 - 3.1 kgf-m)





28. Install the synchronizer split washer.








29. Check clutch hub end play. If clutch hub end play is not within specification, select and install the correct split washer.





30. Install the countershaft reverse gear.
1) Install the countershaft reverse gear.
2) Install the two countershaft reverse gear bearings.
3) Install the reverse synchronizer blocking ring.








31. Measure the countershaft reverse gear end play.
1) Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
2) Determine the correct thrust washer to obtain the correct end play.





32. Install the secondary shaft spacer.





33. Install the secondary shaft reverse gear.





34. Install the reverse idler gear and bushing.
35. Apply silicone sealant to reverse idler shaft bolt threads and install the reverse idler shaft bolt.

Note:
- Reverse idler shaft bolt must be installed within four minutes after applying silicone sealant.





36. Install secondary shaft rear bearing using Shaft Adapter SST 308-033 (T75L-7025-M) (4x4 only) or equivalent and Gear Installing Spacer SST 308-174 (T88T-7025-G) or equivalent.





37. Install the (A) thrust washer and (B) countershaft rear bearing.
38. Lock the transmission into first and third gear.
39. Use Mainshaft Locknut Wrench SST 49 1234 465A to install a new secondary shaft rear bearing lock nut.
Tightening Torque 216 - 274 Nm (21.6 - 27.4 kgf-m, 160 - 202 ft. lbs.)
40. Install a new countershaft locknut.
Tightening Torque 128 - 196 Nm (12.8 - 19.6 kgf-m, 94 - 144 ft. lbs.)





41. Stake the (B) secondary shaft rear bearing lock nut and the (C) countershaft locknut.
42. Apply a small bead of silicone rubber to the extension housing mating surface.

Note:
- Extension housing must be installed within four minutes after applying silicone.

43. Install the extension housing.
1) Position the extension housing.
2) Install the bolts.
Tightening Torque 32 - 46 Nm (3.2 - 4.6 kgf-m, 24 - 33 ft. lbs.)





44. Use Extension Housing Seal Replacer SST 308-002 (T61L-7657-A) or equivalent to install the extension housing seal.
45. Place the synchronizer sleeves in neutral.
46. Apply a small bead of silicone rubber to the case cover mating surface.

Note:
- Case cover must be installed within four minutes after applying silicone.

47. Install the case cover.
1) Position the case cover.
2) Install the bolts.
Tightening Torque 16 - 22 Nm (1.6 - 2.2 kgf-m, 12 - 16 ft. lbs.)