Assembly

Transmission

Countershaft And Reverse Idler Gear Exploded View (Part 1):

Countershaft And Reverse Idler Gear Exploded View (Part 2):

Main Case And Extension Housing View Exploded View:

1. Install the countershaft.
^ Do not install the countershaft front or rear bearings at this time.





2. Position the input shaft into the transmission.





3. Install the output shaft and mate the input shaft and output shaft together. Make sure the 4th gear synchronizer blocking ring and the bearings are in place.





4. Install the center countershaft bearing.





5. Install the output shaft center bearing.





6. NOTE: Install the rear bearing retainer.

Install the rear bearing retainer with the arrow pointing to the top of the case, then install the 6 rear bearing retainer bolts.
^ Tighten to 22 Nm (16 lb-ft).





NOTE: If any related parts (such as the output shaft or bearing) have been installed new, carry-out the shim thickness selective procedure.

7. Using the special tool, install the front cover oil seal.





8. Position the transmission with the bellhousing facing up.
9. Install the front countershaft bearing.
10. Install the input shaft front bearing race.

11. NOTE: A digital caliper is shown being used for the depth measurement. A dial indicator with depth capability or a depth micrometer can also be used.

Measure the input shaft bearing race height.
Record this measurement on line 2 of the selective shim equation chart.





12. Measure the front bearing retainer depth. Record this measurement on line 1 of the selective shim equation chart.





13. Calculate the measurements.

Selective Shim Equation Chart





^ Select the correct output shaft shim to achieve the correct end play. Output shaft end play is 0.05-0.15 mm (0.0019-0.0059 in).
^ Output shaft shim selection:
- 1.4 mm (0.055 in)
- 1.5 mm (0.059 in)
- 1.6 mm (0.063 in)
- 1.7 mm (0.067 in)
- 1.8 mm (0.071 in)
- 1.9 mm (0.075 in)
- 2.0 mm (0.079 in)
- 2.1 mm (0.083 in)
- 2.2 mm (0.087 in)
- 2.3 mm (0.090 in)
- 2.4 mm (0.094 in)
- 2.5 mm (0.098 in)
- 2.6 mm (0.102 in)
- 2.7 mm (0.106 in)
- 2.8 mm (0.110 in)
- 2.9 mm (0.114 in)
- 3.0 mm (0.118 in)
14. Measure and record the countershaft bearing depth.





15. Select the correct countershaft shim.
^ Select the appropriate spacer to achieve the correct end play. Countershaft end play is 0.15-0.25 mm (0.0059-0.0098 in).
^ Countershaft selection shims:
- 3.0 mm (0.118 in)
- 3.1 mm (0.122 in)
- 3.2 mm (0.125 in)
- 3.3 mm (0.129 in)
- 3.4 mm (0.134 in)
- 3.5 mm (0.138 in)
- 3.6 mm (0.142 in)
- 3.7 mm (0.146 in)
16. Apply a light coat of fluid or grease to the countershaft spacer, shim and fluid baffle. Install the bearing shim, fluid baffle and countershaft spacer onto the front bearing retainer.





17. NOTE: Apply a small amount of silicone sealer to the bolt threads.

NOTE: Apply a light coat of fluid to the seal lips. Be careful not to damage the seal when installing the retainer.

Install the front bearing retainer and the 6 front bearing retainer bolts.
^ Tighten to 22 Nm (16 lb-ft).








18. NOTE: Apply a small amount of silicone sealer to the bolt threads.

Install the fluid passage and the fluid passage bolt.
^ Tighten to 9 Nm (80 lb-in).





19. Install the output shaft 5th speed gear.





20. Install the following components:
^ Locating ball
^ Inner race
^ 5th speed gear split bearing





21. Install the countershaft 5th speed gear.





22. Position the counter lever shaft and plate, then install the counter lever lock plate bolt.
^ Tighten to 9 Nm (80 lb-in).





23. Install the 5th/reverse shift lever, the washer and the 5th/reverse shift retaining ring.





24. Install the countershaft 5th gear synchronizer blocking ring.





25. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.

Install the 5th/reverse shift rail, the shift fork and the 5th/reverse synchronizer assembly.





26. Install the 5th/reverse shift rail bolt.
^ Tighten to 25 Nm (18 lb-ft).





27. Install the countershaft split washer.





28. Check clutch hub end play.
^ If clutch hub end play is not within specification, select and install the correct split washer.
^ Split washer selection:
- 3.0 mm (0.118 in)
- 3.1 mm (0.122 in)
- 3.2 mm (0.125 in)
- 3.3 mm (0.129 in)
- 3.4 mm (0.133 in)
- 3.05 mm (0.120 in)
- 3.15 mm (0.124 in)
- 3.25 mm (0.127 in)
- 3.35 mm (0.131 in)





29. Install the reverse gear thrust washer.





30. Install the following:
1 Reverse synchronizer blocking ring
2 Two countershaft reverse gear bearings
3 Countershaft reverse gear





31. Measure the countershaft reverse gear end play.
^ Install the thrust washer and hold it against the shoulder on the countershaft while checking end play.
^ Determine the correct thrust washer to obtain correct end play.
^ Thrust washer selection:
- 7.35 mm (0.289 in)
- 7.45 mm (0.293 in)
- 7.55 mm (0.297 in)
- 7.65 mm (0.301 in)
- 7.75 mm (0.305 in)
- 7.85 mm (0.309 in)





32. Install the output shaft spacer.





33. Install the output shaft reverse gear.





34. Install the reverse idler gear and bushing.





35. Apply threadlock and sealer to the reverse idler shaft bolt, install the bolt.
^ Tighten to 98 Nm (72 lb-ft).





36. Position the output shaft rear bearing on the output shaft. Using the old output shaft locknut, install the output shaft rear bearing. Discard the nut.





37. Install the thrust washer and countershaft rear bearing.





38. Lock the transmission into 1st and 3rd gear.





39. Install a new output shaft locknut.
^ Tighten to 245 Nm (181 lb-ft).





40. Install a new countershaft locknut.
^ Tighten to 162 Nm (119 lb-ft).





41. Using the special tool, stake the output shaft locknut and the countershaft locknut.





42. Position the locating ball on the shaft, install the output shaft speed (OSS) tone ring, then install the snap ring.
43. Apply a small bead of ultra silicone sealant to the extension housing mating surface.
44. Install the extension housing and the extension housing bolts.
^ Tighten to 39 Nm (29 lb-ft).
45. Using the special tool, install a new extension housing seal.





46. Place the synchronizer sleeves in NEUTRAL.





47. Install the shift control housing seal.





48. Install the case cover and the 10 case cover bolts.
^ Tighten to 19 Nm (14 lb-ft).





49. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
^ Tighten to 20 Nm (15 lb-ft).