Assemble

1. Lubricate countershaft gear thrust surfaces and position a thrust washer at each end of case. Place countershaft gear, dummy shaft and roller bearings in the case.
2. Place case in the vertical position, align gear bore and thrust washers with case bores and install countershaft.
3. Place case in the horizontal position and, with a feeler gauge, check countershaft gear end play which should be 0.004-0.018 inch. If not, replace thrust washers.
4. Reinstall dummy shaft in countershaft gear and place gear at bottom of case.
5. Lubricate reverse idler gear thrust surfaces and place the two thrust washers in position. Install reverse idler gear, sliding gear, dummy shaft and roller bearings in place, ensuring the sliding gear shift fork groove is facing toward front of case. Align gear bore and thrust washers with case bores and install the reverse idler shaft.
6. With a feeler gauge, check reverse idler gear end play which should be 0.004-0.018 inch. If not, replace thrust washers. If end play is within limits, do not remove gear and shaft.
7. Install reverse gear shift rail detent spring and detent plug into case. Holding reverse shift fork in place on the reverse idler sliding gear, install the shift rail from rear of case. Install shift rail to fork set screw.
8. Place first and second speed synchronizer onto output shaft with shift fork groove facing toward rear of shaft. The synchronizer hub is installed with the teeth end of the gear facing toward rear of output shaft.
9. Place blocking ring on second speed gear, then slide the gear onto front of output shaft, ensuring synchronizer inserts engage the blocker ring notches.
10. Install second speed gear thrust washer and snap ring.
11. Slide overdrive gear onto shaft with coned surface facing toward front of output shaft, then install blocking ring on gear.
12. Slide third and overdrive gear synchronizer onto shaft, ensuring synchronizer inserts engage blocking ring notches and the thrust surface is facing toward overdrive gear.
13. Install snap ring at front of output shaft.
14. Place blocking ring on first speed gear, then slide first speed gear onto rear of output shaft, ensuring synchronizer inserts engage blocking ring notches.
15. Install the heavy thrust washer at rear of output shaft.

Removing Output Shaft Assembly:

16. Support thrust washer and first speed gear to prevent washer and gear from sliding off shaft and lower assembly into case.
17. Install first and second speed shift fork and the third and overdrive speed shift fork, rotating forks into place.
18. Install detent spring and plug into reverse shift rail, then place rail in neutral position.
19. Lubricate third and overdrive shift rail interlock pin and install in shift rail.
20. Align third and overdrive shift fork with shift rail bores and slide shift rail into position, ensuring the three detents are facing toward outside of case. Place front synchronizer into neutral position and install the third and overdrive shift fork set screw. Place synchronizer in neutral position and install the third and overdrive shift rail detent - plug, spring and bolt into left side of case. Install detent plug into case bore.
21. Align first and second speed shift fork with case bores and slide shift rail into place, then install set screw.
22. Lubricate input gear bore and install 15 roller bearings into bore.

NOTE: Apply a thin coat of lubricant since a heavy application may plug the lubricant holes and restrict lubrication of the bearings.

23. Place front blocking ring in the third and overdrive synchronizer.
24. Place a dummy bearing on rear of output shaft to support and align shaft in case.
25. Install input shaft gear into case, ensuring output shaft pilot enters roller bearings in input gear pocket.

Input Shaft Assembly:

26. Place input shaft bearing on input shaft and press bearing onto shaft and into case bore.
27. Install input shaft and bearing snap rings.
28. Place new gasket on input shaft bearing retainer, apply sealer to attaching bolts and install and torque attaching bolts to 19-25 ft lbs (25-33 Nm).
29. Remove dummy bearing from output shaft and install output shaft bearing onto shaft and press into case bore.

NOTE: Before pressing bearing onto output shaft, ensure the bearing is aligned with the case bore and the countershaft is not interfering with the output shaft assembly.

30. Install output shaft and bearing snap rings.
31. Place transmission in the vertical position. Align countershaft gear bore and thrust washers with case bore and install countershaft.
32. Install extension housing on case with a new gasket, apply sealer to attaching screws and install and torque to 42-50 ft lbs (56-67 Nm).
33. Install filler plug.
34. Pour transmission lubricant over gear train while rotating input shaft.
35. Place each shift fork in all positions to ensure proper operation.
36. Install remaining detent plug in case and the long spring to secure detent plug.
37. Install cover with a new gasket, apply sealer to attaching screws and install and torque attaching screws to 20-25 ft lbs (27-33 Nm).
38. Apply sealer to the third and overdrive shift rail plug bore and install new expansion plug.