Shift Mechanism and Geartrain
DISASSEMBLYRemove Fifth Gear Snap Ring:
1. Install suitable bolts and washers in intermediate plate. Then clamp plate and gear assembly in vise. Use enough washers to prevent bolts from touching. Also be sure vise jaws are clamped on bolt heads.
2. Measure thrust clearance between countershaft fifth gear and thrust ring with feeler gauge. Clearance should be 0.10 to 0.40 mm. (0.003 to 0.019 inch). If clearance exceeds limits, gear and/or ring will have to be replaced.
Positioning Intermediate Plate In Vise:
3. Remove countershaft fifth gear retaining snap-ring.
Remove Fifth Gear Shift Fork Retainer Bolt:
4. Remove bolt holding fifth gear shift fork to shift rail.
5. Move fifth gear shift rail forward until the rail is clear of the shift fork.
Remove Fifth Gear Shift Fork:
6. Remove the fifth gear shift fork from the synchronizer sleeve.
Remove Rever Shift Head Assembly:
7. Remove the reverse shift head and rail assembly from the intermediate plate.
Remove Fifth Gear Blocker Ring:
8. Remove fifth gear blocker ring from countershaft assembly with Puller L-4407.
Remove Fifth Gear Synchro Ring:
9. Remove fifth gear synchro ring.
Remov Fifth Gear And Synchro Assembly:
10. Remove the countershaft fifth gear assembly from countershaft.
Remove Fifth Gear Thrust Ring:
11. Remove fifth gear thrust ring from countershaft.
Remove Fifth Gear Thrust Ring Lock Ball:
12. Remove fifth gear thrust ring lock ball from countershaft.
NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission. Whenever a pin or ball is removed, it should be identified in such a way that it can be reinstalled in the same location from which it was removed.
Remove Outputshaft Rear Bearing Retainer Bolts:
13. Remove bolts holding output shaft rear bearing retainer to intermediate plate.
Remove Outut Shaft Rear Bearing Retainer:
14. Remove rear bearing retainer.
Remove Reverse Idler Shaft And Gear:
15. Remove reverse idler gear shaft and gear.
Reverse Shift Arm Components:
16. Remove bolts holding reverse shift arm bracket to intermediate plate.
Lock Ball Plug Locations:
17. Remove threaded lock ball plugs from intermediate plate.
18. Then remove lock ball and spring from plug holes with pencil magnet.
Shift Rail Identification:
19. Remove the fifth gear shift rail.
Remove Fifth Gear Shift Rail Lock Ball:
20. Retrieve the fifth gear shift rail lock ball from the intermediate plate using a magnet.
Remove Shift Rail C-Rings:
21. Remove the 1-2 and 3-4 shift rail c-rings using two equally sized screwdrivers.
Remove Shift Frk To Shift Rail Bolts:
22. Remove bolts holding 1-2 and 3-4 shift forks to the shift rails and discard bolts.
Remove 3-4 Shift Rail:
23. Remove the 3-4 shift rail from the 1-2 and 3-4 shift forks and the intermediate plate.
Remove 3-4 Shift Rail Interlock Plug:
24. Remove the 3-4 shift rail interlock plug from the intermediate plate with a small magnet.
Remove Shift Forks:
25. Remove the 3-4 shift fork.
Remove 1-2 Shift Rail:
26. Remove the 1-2 shift rail from the 1-2 shift fork and the intermediate plate.
Remove 1-2 Shift Rail Interlock Pin:
27. Remove the 1-2 shift rail interlock pin from the 1-2 shift rail.
Remove 1-2 Shift Rail Interlock Plug:
28. Remove the 1-2 shift rail interlock plug from the intermediate plate.
29. Remove the 1-2 shift fork.
Remove Reverse Shift Rail C-Ring:
30. Remove the c-ring holding the reverse shift rail into the intermediate plate using two equally sized screwdrivers.
Remove Reverse Shift Rail:
31. Remove the reverse shift rail and fork from the intermediate plate.
Remove Reverse Shift Rail Interlock Pin:
32. Remove the interlock pin from the reverse shift rail.
Remove Output Shaft Rear Bearing Snap-Ring:
33. Remove snap-ring holding output shaft rear bearing into the intermediate plate.
34. Remove countershaft rear bearing snap-ring.
Remove Mainshaft:
35. With aid of an assistant, support the mainshaft and countershaft. Tap on the rear of the mainshaft and countershaft with a suitable rubber mallet. This will release the countershaft from the countershaft rear bearing and the mainshaft rear bearing from the intermediate plate. The mainshaft will release from the intermediate plate first and can be removed by moving the mainshaft rearward and upward.
36. Remove the countershaft by moving the countershaft rearward until the countershaft, is clear of the intermediate plate.
37. Remove the countershaft rear bearing from the intermediate plate.
ASSEMBLY
1. Lubricate countershaft journal and rear bearing with petroleum jelly or gear lubricant.
2. Position the mainshaft into the intermediate plate.
3. Tap the mainshaft assembly rear bearing into the intermediate plate with a suitable rubber mallet.
4. Install the countershaft thru the countershaft rear bearing journal of the intermediate plate.
5. Align and mesh the mainshaft and countershaft gears as much as possible.
6. Install the countershaft bearing over the countershaft bearing boss and into the intermediate plate. Be sure to leave the snap-ring groove in the bearing facing the rear of the unit. It may be necessary to tap on the bearing with a plastic mallet to fully seat the bearing into intermediate plate.
7. Verify that the mainshaft and countershaft gears are correctly meshed and rotate properly.
8. Install snap-ring to hold output shaft rear bearing into the intermediate plate.
9. Install countershaft rear bearing snap-ring.
NOTE: Coat all shift components with petroleum jelly during assembly. Petroleum jelly will hold components in position during installation.
Install Reverse Shift Rail Interlock Pin:
10. Install interlock pin in reverse shift rail.
Install Reverse Shift Rail:
11. Install the reverse shift rail in the intermediate plate.
12. Install c-ring to hold the reverse shift rail into the intermediate plate.
13. Install the 1-2 and 3-4 shift forks into the synchronizer sleeves.
Install 1-2 Shift Rail Interlock Plug:
14. Install 1-2 shift rail interlock plug in the intermediate plate.
Install 1-2 Shift Rail Interlock Pin:
15. Install interlock pin in 1-2 shift rail.
Install 1-2 Shift Rail:
16. Install 1-2 shift rail through intermediate plate and 1-2 shift fork.
Install 3-4 Shift Rail Interlock Plug:
17. Install 3-4 shift rail interlock plug into the intermediate plate.
Install 3-4 Shift Rail:
18. Install the 3-4 shift rail through the intermediate plate, 1-2 and 3-4 shift forks.
Install Shift Fork To Shift Rail Bolts:
19. Install new bolts to hold the shift forks to the shift rails.
Install Shift Rail C-Rings:
20. Install c-rings to 1-2 and 3-4 shift rails.
Install Fifth Gear Shift Rail Lock Ball:
21. Install the fifth gear shift rail lock ball in the intermediate plate.
22. Install the fifth gear shift rail into the intermediate plate.
Install Reverse Idler Gear And Shaft:
23. Install reverse idler gear and idler gear shaft. Verify that the notch in the idler shaft is to the rear of the transmission.
24. Position output shaft rear bearing retainer on intermediate plate and into reverse idler shaft notch.
Install Output Hsaft Rear Bearing Retainer:
25. Install new bolts to hold retainer to intermediate plate.
Install Fifth Gear Thrust Ring Lock Ball:
26. Install the fifth gear thrust ring lock ball into the countershaft.
Install Fifth Gear Thrust Ring:
27. Install fifth gear thrust ring onto countershaft and over lock ball.
Install Countershaft Fifth Gear Bearings:
28. Install countershaft fifth gear bearing halves into countershaft fifth gear assembly.
Install Countershaft Fifth Gear Assembly:
29. Install countershaft fifth gear assembly onto countershaft.
Install Fifth Gear Synchronizer Ring:
30. Install fifth gear synchronizer ring.
31. Position fifth gear blocker ring onto countershaft. Verify that blocker ring and countershaft splines are aligned.
32. Using a suitable driver and mallet, seat the blocker ring onto the countershaft.
33. Select the thickest snap-ring the will fit into the snap-ring groove of the countershaft.
Install Fifth Gear Snap-Ring:
34. Install snap-ring to hold the countershaft fifth gear assembly onto the countershaft.
Install Reverse Shift Head And Rail Assembly:
35. Install the reverse shift head and rail assembly.
Install Fifth Gear Shift Fork:
36. Move reverse shift rail forward as far as possible and install fifth gear shift fork onto synchronizer sleeve.
Install Fifth Gear Shift Fork Retainer Boltt:
37. Install new bolt to hold fifth gear shift fork to shift rail.
38. Install detent balls and springs into openings in the intermediate plate.
39. Install new lock ball plugs into the intermediate plate. Tighten plugs to 19 Nm (14 ft. lbs.).
40. Install bolts to hold reverse shift arm to the intermediate plate. Tighten bolts to 18 Nm (13 ft. lbs.).