Assembly
Transmission
Assembly
1. Install the countershaft cluster gear.
2. Position the input shaft.
3. NOTE: Make sure the 4th gear synchronizer blocking ring is in place.
Install the output shaft.
4. Mate the input shaft and output shaft together.
5. Install the countershaft pilot bearings on both ends.
6. Install the output shaft rear bearing and input shaft bearing.
7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
Install the rear bearing retainer and bolts.
^ Tighten to 22 Nm (16 lb-ft).
8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.
Using the special tool, install the front cover oil seal.
9. Position the transmission with the bell housing facing up.
10. Using the special tool, measure the input shaft bearing race depth.
^ Record the reading on Line 2 of the selective shim equation chart.
11. Using the special tool, measure the front bearing retainer depth.
^ Record the reading on Line 1 of the selective shim equation chart.
12. Calculate and select the correct output shaft shim Refer to the Output Shaft Shim Selective Chart.
Selective Shim Equation Chart
Selective Shim Equation Chart:
Output Shaft Shim Selective Chart
Output Shaft Shim Selective Chart (Part 1):
Output Shaft Shim Selective Chart (Part 2):
13. Using the special tool, measure the countershaft bearing depth.
^ Record the reading on Line 1 of the countershaft spacer equation chart.
14. Using the special tool, measure the countershaft bearing retainer depth.
^ Record the reading on Line 2 of the countershaft spacer equation chart.
15. Calculate and select the correct countershaft spacer. Refer to the Countershaft Spacer Selective Chart.
Countershaft Spacer Equation Chart
Countershaft Spacer Equation Chart:
Countershaft Spacer Selective Chart
Countershaft Spacer Selective Chart (Part 1):
Countershaft Spacer Selective Chart (Part 2):
16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.
Position the bearing shim the fluid baffle and the countershaft spacer onto the front bearing retainer.
^ Using gasket maker, apply a thin coat to the sealing surface of the case and the front bearing retainer.
17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.
NOTE: Apply silicone sealant to the bolt threads.
Install the front bearing retainer.
^ Tighten to 19 Nm (14 lb-ft).
18. Position the oil passage.
19. NOTE: Apply silicone sealant to the bolt threads.
Install the front oil cooler tube bolt.
^ Tighten to 9 Nm (80 lb-inch).
20. Install the output shaft 5th gear.
21. Install the locking ball.
22. Install the race and the 5th gear split needle bearing on the countershaft.
23. Install the countershaft 5th gear and the countershaft 5th gear synchronizer blocking ring.
24. 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 synchronizer as an assembly.
25. Install the 5th/reverse shift lever into the case.
26. Install the counter lever shaft assembly.
^ Tighten to 45 Nm (33 lb-ft).
^ Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.
27. Install the 5th/reverse gear shift rail bolt.
^ Tighten to 25 Nm (18 lb-ft).
28. Install the synchronizer split washer.
29. Using a feeler gauge, check the clutch hub end play.
^ If the clutch hub end play is not within specification, select and install the correct split washer.
Split Washer Select Chart
Split Washer Select Chart (Part 1):
Split Washer Select Chart (Part 2):
30. The reverse gears are not serviced separately. A kit consisting of the output shaft reverse gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the kit must be installed. The replacement gears are not compatible with the existing gears.
1 Output shaft reverse gear.
2 Countershaft reverse gear.
3 Reverse idler gear.
31. Install the following:
^ Thrust washer
^ Two countershaft reverse gear needle bearings
^ Countershaft reverse gear
32. Measure the countershaft reverse gear end play.
^ Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
^ Determine the correct thrust washer to obtain the correct end play. Remove the reverse gear and install the appropriate thrust washer. Reinstall the reverse gear.
Thrust Washer Select Chart
Thrust Washer Select Chart:
33. Install the output shaft spacer.
34. Install the output shaft reverse gear.
35. Install the reverse idler gear.
36. NOTE: Reverse idler shaft bolt must be installed within 4 minutes after applying the thread sealant with PTFE.
Install the reverse idler shaft bolt.
^ Tighten to 98 Nm (72 lb-ft).
^ Apply thread sealant to the reverse idler shaft bolt threads.
37. Using the special tools, install the output shaft rear bearing.
38. Install the thrust washer and the countershaft rear bearing.
39. Lock the transmission into 1st, and 3rd gear.
40. Using the special tool, install a new countershaft locknut.
^ Tighten to 162 Nm (119 lb-ft).
41. Using the special tool, install a new output shaft rear bearing locknut.
^ Tighten to 216 Nm (159 lb-ft).
42. Using the special tool, stake the output shaft rear bearing locknut and the countershaft locknut.
43. Install the locating ball, the tone wheel and the tone wheel snap ring.
44. Install the extension housing.
^ Apply gasket maker to the mating surfaces before installing.
^ Tighten to 39 Nm (29 lb-ft).
45. Using the special tool, install the extension housing seal.
46. Place the synchronizer sleeves in neutral.
47. Install the case cover gasket.
48. Install the case cover.
^ Tighten to 19 Nm (14 lb-ft).
49. If equipped, install the damper.
^ Tighten to 22 Nm (16 lb-ft).