Adapter/Extension Housing and Front Bearing Retainer
DISASSEMBLY1. Drain transmission lubricant, if necessary.
2. Remove release bearing and lever.
Clutch Housing:
3. Remove clutch housing bolts and remove housing.
4. Remove bolts holding shift tower to transmission case.
Remove Shift Tower:
5. Remove shift tower from transmission case.
Remove Shift Tower Gasket:
6. Remove shift tower gasket from shift tower or transmission case.
Remove Detent Ball Plug:
7. Remove reverse shift head detent ball plug.
Remove Detent Spring:
Remove Detent Ball:
8. Remove detent ball spring and ball with pencil magnet.
Shift Arm Retainer Bolt Removal:
9. Remove shift arm retainer bolt.
Shift Arm Restrictor Pins:
10. Remove shift arm restrictor pins.
Removing Shift Lever Shaft Plug:
11. Remove shift lever shaft plug.
Remove Shifter Shaft:
12. Remove shifter shaft with large magnet.
13. Remove the shift arm from the adapter housing.
14. Remove adaptertension housing bolts.
Loosen Adapter/Extension Housing:
15. Loosen adaptertension housing by tapping it loose with plastic mallet.
Remove Adapter/Extension Housing:
16. Remove adaptertension housing.
17. Remove the bolts holding the front bearing retainer to the transmission case.
Remove Front Bearing Retainer:
18. Remove the bearing retainer from transmission case.
Remove Input Shaft Bearing Snap-Ring:
19. Remove input shaft bearing snap-ring.
Remove Cluster Gear Snap-Ring:
20. Remove cluster gear bearing snap-ring.
Separate Intermediate Plate And Transmission Case:
21. Separate intermediate plate and transfer case by tapping them loose with plastic mallet.
Remove Intermediate Plate From Transmission Case:
22. Separate the intermediate plate from the transmission case.
ASSEMBLY
1. Remove any residual sealer from transmission case, intermediate plate, adaptertension housing, and front bearing retainer.
Apply Sealer To Transmission Gear Case:
2. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket TB1281, P/N 83504038, as shown, making sure to keep sealer bead to inside of bolt holes.
Install Transmission Gear Case To The Intermediate Plate:
3. Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate. Verify that the transmission case is seated on the intermediate plate.
Install Front Bearing Snap-Rings:
4. Install new front bearing snap rings.
5. Apply 1/8 inch wide bead of Threebond Liquid Gasket TB1281, P/N 83504038, to the front bearing retainer sealing surface.
Install Front Bearing Retainer:
6. Install the front bearing retainer and tighten bolts to 17 Nm (12 ft. lbs.).
7. Apply a 1/8 to 3/16 inch wide bead of Threebond Liquid Gasket TB1281, P/N 83504038, to sealing surface of adaptertension housing, making sure to keep sealer bead to inside of bolt holes.
Install Adpater/Extension Housing:
8. Install adapter or extension housing on intermediate plate. Tighten housing bolts to 37 Nm (27 ft. lbs.) torque.
Position Shaft Arm In Transmission Case:
9. Position shift arm in shifter tower opening of adaptertension housing. Be sure that the shifter arm is engaged into the shift rails.
Install Shifter Arm Shaft:
10. Start shifter arm shaft in hole in back of adaptertension housing. Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adaptertension housing.
11. Rotate the shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft.
Install Shift Arm Retainer Bolt:
12. Install the shift arm retainer bolt and tighten to 38 Nm (28 ft. lbs.).
Shifter Arm Shaft Plug Installation:
13. Install and tighten shifter arm shaft, plug to 18 Nm (13 ft. lbs.) torque.
Install Shifter Restrictor Pins:
14. Install shifter restrictor pins in shift tower and tighten to 27 Nm (20 ft. lbs.).
Install Detent Ball:
15. Install shift detent ball in detent opening.
Install Detent Spring:
16. Install detent spring.
Install Dtent Bll Plug:
17. Install detent plug and tighten to 19 Nm (14 ft. lbs.).
Installing Shift Tower And Backup Lamp Switch:
18. Install shift tower and new gasket on housing. Tighten tower bolts to 18 Nm (13 ft. lbs.) torque.
19. Install new metal o-ring to the backup lamp switch.
20. Install backup lamp switch. Tighten switch to 37 Nm (27 ft. lbs.) torque.
21. Install new seal in adaptertension housing.
22. Install clutch housing, release bearing, release fork and retainer clip.