Assembly

NOTE:
- The shift rail interlock pins, balls and plugs must be installed in the correct sequence for proper shifting. Refer to the installation diagram during assembly.

- Coat the intermediate plate shift rail bores and the interlock balls, pins and plugs with a thick covering of petroleum jelly before assembly. The jelly will hold the interlock components in place making installation easier. Use a pencil magnet to hold and insert the interlocks. Then use a small screwdriver to push the inter lock components into place.





PROCEDURE
1. Coat reverse rail interlock pin with petroleum jelly and install pin in rail.





2. Install reverse shift rail in intermediate plate.





3. Install reverse shift rail C-ring.





4. Position 1-2 and 3-4 shift forks in synchro sleeves.





5. Coat reverse rail lock ball with petroleum jelly. Then tilt reverse shift fork upward and insert ball in intermediate plate.





6. Coat 1-2 shift rail interlock plug with petroleum jelly and install it in intermediate plate bore.





7. Coat 1-2 shift rail interlock pin with petroleum jelly and insert it in shift rail.





8. Install 1-2 shift rail in intermediate plate and 1-2 fork.





9. Coat 3-4 shift rail interlock plug with petroleum jelly and install plug in intermediate plate.





10. Install 3-4 shift rail in intermediate plate and in both shift forks.
11. Verify that none of the interlock balls, plugs, or pins were displaced during shift rail installation.





12. Install and tighten shift fork setscrews to 20 Nm (14 ft. lbs.) torque.





13. Install 1-2 and 3-4 shift rail C-rings.
14. Insert fifth gear shift rail through reverse shift fork. Then slide rail into intermediate plate just far enough to secure interlock ball. Do not fully install shift rail at this time.