Warner T5 (77mm) 5-Speed
1. Install front countershaft bearing, if removed, as follows:
a. Lubricate O-ring, then install O-ring onto bearing race.
b. Coat bearing race outside diameter with Loctite 601 or equivalent, then position bearing race to case.
c. Using a press, Universal Driver Handle tool No. J-8092 and Countershaft Race Installer tool No. J-37357 or equivalents, press bearing race into case until flush with case.
2. Coat counter gear rear bearing thrust washer with grease, then place thrust washer on countershaft assembly.
3. Position countershaft assembly in case, then tip case on end, place two � inch thick pieces of bar stock under countershaft.
4. Coat rear countershaft bearing with grease, then position bearing on countershaft.
5. Using a press and Bearing Installer tool No. J-29895 or equivalents, press bearing on countershaft.
6. Remove bar stock from under countershaft, then seat countershaft in front bearing. Measure countershaft rear bearing. Bearing should extend 0.125 inch (3mm) past the transmission case.
7. Install rear countershaft bearing race onto countershaft, then countershaft retainer.
8. Install countershaft retaining bolts, then torque to 11-20 ft. lbs. This should be done initially without shims.
9. Measure endplay using Universal Dial Indicator tool No. J-8001 or equivalent. Remove retainer and install shim(s) as necessary. Zero end play with no preload is preferable, but up to 0.004 inch end play is allowable.
10. Reinstall bearing retainer, then tighten retaining bolts as previously specified, then bend tabs on bearing retainer over bolts.
11. Ensure countershaft endplay is as specified. Adjust if necessary.
12. Position reverse idler gear in case with shift lever groove facing rear of case.
13. Install reverse idler shaft and rubber overtravel stop (O-ring). Install shaft from rear of case, then position overtravel stop between gear and shaft support.
14. Using a 3/16 inch (5mm) pin punch, install reverse idler shaft roll pin.
15. If removed, apply Pipe Sealant with Teflon or equivalent to inhibitor spring anchor pin threads, then install anchor pin and torque to 6-11 ft. lbs.
16. Align fifth/reverse shift lever, reverse shift fork and inhibitor spring as shown.
17. Install shift lever and fork in case, connect looped end of inhibitor spring on anchor pin.
18. Position reverse idler gear into the neutral position, then align reverse shift fork with reverse idler gear. Push downward on shift fork until fully engaged into reverse idler gear. Observe inhibitor spring rotation. Spring should rotate counterclockwise into its installed position.
19. Install output shaft assembly in case.
20. Coat the 15 input shaft roller bearings, thrust bearing and race with multi purpose grease or equivalent, then install components on input shaft.
21. Align notches in blocking ring with inserts in 3rd/4th synchronizer inside case, then install blocking ring on synchronizer.
22. Install input shaft. Align flat on synchronizer teeth with countershaft before installing input shaft. Ensure blocking ring is still in correct position.
23. Install bearing race in bearing retainer. Do not install shim(s) at this time.
24. Temporarily, install bearing retainer with narrow or smaller notch facing upward. Do not apply sealant at this time.
25. Torque retaining bolts to 11-20 ft. lbs.
26. Install output shaft rear bearing race. Tap bearing race into position using a plastic faced hammer, if necessary.
27. Install fifth/reverse shift rail into front of transmission case by aligning ball stud in slot in case and aligning shift rail with reverse fork. When ball stud is just entering case, rotate shift rail clockwise and push shift rail until ball stud aligns with fifth/reverse shift lever. Rotate shift rail counterclockwise until ball stud fully engages shift lever.
28. Install fifth gear, synchronizer and shift fork as an assembly.
29. Install fifth gear blocking ring, brake ring, retainer and snap ring. Ensure tabs on retainer engage splines of countershaft.
30. Apply pipe sealant with Teflon or equivalent, to the pivot pin threads, then install pivot pin. Torque pivot pin to 11- 20 ft. lbs.
31. Apply pipe sealant with Teflon or equivalent, to back-up lamp switch, then install switch. Torque switch to 20 ft. lbs.
32. Using needle nose pliers, install C-clip on shift lever pivot pin.
33. Install speedometer gear on output shaft. The tab on the gear engages a hole in the output shaft.
34. Apply 1/8 inch (3mm) bead of Silicone Rubber sealant or equivalent, to shift cover assembly. Do Not apply sealant to transmission case, as sealant could fall into transmission and effect operation.
35. Ensure all synchronizers are in neutral position and that shift forks in the cover are in neutral. Position shift cover to filler plug side of transmission and lower into position until shift forks engage synchronizers. Continue lowering cover and move into position to engage fifth/reverse shift lever.
36. Install shift cover retaining bolts, then torque to 6-11 ft. lbs.
37. Apply 1/8 inch (3mm) bead of Silicone Rubber sealant or equivalent, to extension housing mating surface.
38. Coat detent spring with petroleum jelly, then install in offset lever. Lubricate detent plate and install detent ball in neutral position on plate.
39. Position offset lever in extension housing with spring over detent ball.
40. Press downward on offset lever to compress detent spring, then install slide extension housing and offset lever onto transmission case.
41. Install extension housing retaining bolts, then torque retaining bolts to 3O-45 ft. lbs.
42. Using a suitable pin punch, align the hole in shifter shaft with hole in offset lever, then install roll pin.
43. Install damper sleeve in offset lever.
44. Check output shaft geartrain endplay as follows:
a. Place transmission in vertical position with extension housing up.
b. Mount Universal Dial Indicator tool No. J-8001 or equivalent, on the extension housing with the indicator stylus contacting the output shaft. Rotate the input and output shafts. Zero the dial indicator.
c. Using a wood block, push upward on the input shaft, then note dial indicator reading.
d. A shim must be installed that is the thickness (plus or minus 0.002 inch) of the dial indicator reading. Do not overload the bearings with too thick a shim.
e. Place transmission to horizontal position
45. Place transmission to horizontal position, then remove front bearing retainer.
46. Remove bearing race from retainer, then install necessary shim(s).
47. Apply 1/8 inch (3mm) bead of Silicone Rubber sealant or equivalent, to bearing retainer mating surface. Sealant must not cover the small notch in the bearing retainer.
48. Install bearing retainer with small notch facing upward, then torque retaining bolts to 11-20 ft. lbs.
49. Apply 1/8 inch (3mm) bead of Silicone Rubber sealant or equivalent, to transmission shift control cover, then position cover on extension housing.
50. Torque shift control cover retaining bolts to 12-15 ft. lbs.
51. Install drain plug, then torque to 12-22 ft. lbs.