Shift Shaft, Lever and Bushing and Shift Socket Installation

SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATION
1. Before proceeding, verify that all synchro sleeves are in Neutral position (centered on hub). Move sleeves into neutral if necessary

CAUTION: The transmission synchros must all be in Neutral position for proper reassembly. Otherwise, the housings, shift forks and gears can be damaged during installation of the two housings.

Installing 3-4 Shift Fork:

2. Install 3-4 shift fork in synchro sleeve. Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as. shown.

Shift Shaft Installation:

3. Slide shift shaft through 3-4 shift fork. Be sure shaft detent notches are to front.

Assembling Shift Shaft Lever And Bushing:

4. Assemble shift shaft shift lever and bushing. Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.

Installing Shift Shaft Lever Andbushing:

5. Install assembled lever and bushing on shift shaft.

Inserting Shaft Into Lever Opening In Housing:

6. Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing.

Shift Socket Installation:

7. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing.
8. Rotate shift shaft so detent notches in shaft are facing driver side of housing.

CAUTION: Correct positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.

Roll Pin Identification-Shaft Lever And Shift Socket:

9. Select correct new roll pin for shift shaft lever. Shaft lever roll pin is approximately 22 mm (7/8 inch) long. Shift socket roll pin is approximately 33 mm (1-1/4 inch) long.

Starting Roll Pin In Shift Shaft Lever:

10. Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand.

Correct Seating Of Shift Shaft Lever Roll Pin:

11. Seat shaft lever roll pin with pin punch.

CAUTION: The shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.

12. Before proceeding, verify that lock pin slot in lever bushing is positioned as shown.

Starting Roll Pin In Shift Socket:

13. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand.

Seating Shift Socket Roll Pin:

14. Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation.

Shaft Lever Positioned For Detent Ball And Spring Installation:

15. Verify that notches in shift fork arms are aligned. Realign arms if necessary.
16. Rotate shaft lever and bushing downward (out of fork arms), to expose detent bore in lever.

Installing Detent Spring In Shaft Lever:

17. Insert detent spring in lever bore.

Installing Detent Ball In Shaft Lever:

18. Install detent ball on top of spring in lever bore.
19. Press and hold detent ball in lever. Then carefully rotate lever upward into fork arm notches. Be sure ball is seated in fork arms before proceeding.