Geartrain Assembly In Fixture

GEARTRAIN ASSEMBLY IN FIXTURE

Preparing Assembly Fixture For Geartrain Buil-up:

1. Install Adapter 6747-1A on input shaft hub of fixture tool. Then install Adapter 6747-2A on front bearing hub of countershaft. Adapter 6747-2A has a raised shoulder on one side. Be sure the shoulder is seated against the countershaft.

Installing Pilot Bearing In Input Shaft:

2. Install input shaft in fixture tool. Make sure Adapter Tool 6747-IA is positioned under shaft as shown.
3. Install pilot bearing in input shaft.

Installing Fourth Gear Synchro Ring On Input Shaft:

4. Install fourth gear synchro ring on input shaft.

Idler Pedestal Basic Height Adjustment:

5. Adjust height of idler gear pedestal on assembly fixture. Start with a basic height of 18.4 cm (7-1/4 inch). Final adjustment can be made after gear is positioned on pedestal.

Output Shaft And Geartrain Installed In Input:

6. Install assembled output shaft and geartrain in input shaft. Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
7. Install Adapter 6747-2A on front bearing hub of countershaft, if not previously done. The adapter has a shoulder on one side. The shoulder goes toward the countershaft.

Countershaft Installed On Fixture Tool:

8. Slide countershaft (and adapter) into fixture slot. Verify that countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding.
9. Check alignment of countershaft and output shaft gear teeth. Note that gears may not align perfectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 inch) will probably exist. This difference will not interfere with assembly. However, if the difference is greater than this, the countershaft adapter tool is probably upside down. Remove countershaft, reverse adapter tool, reinstall countershaft; and check alignment again.

Reverse Ider Assembly Positioned On Assembly Fixture Pedestal:

10. Position reverse idler in support cup of assembly fixture. Be sure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary. Also be sure that short end of idler shaft is facing up as showing.

Positioning Output Shaft Bearing Retainer For Rear Housing Installation:

11. On 2-wheel drive transmission, thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown.

Assembling 1-2 And Fifth-Reverse Shift Forks:

12. Assemble 1-2 and fifth reverse-shift forks. Arm of fifth-reverse fork goes through slot in 1-2 fork.

Shift Forks Installed Insynchro Sleeves:

13. Install assembled shift forks in synchro sleeves. Be sure forks are properly seated in sleeves.