Transmission Case Assembly
Assembly - Transmission CaseCAUTION: Except for the gearshift lever attaching bolts and filler plug, all bolts and threaded holes used in the T5 transmission have metric dimensions. Do not attempt to substitute with a different thread-type or size bolt if an original bolt is damaged or lost.
Coat the countershaft front bearing outer cage with Loctite 601, or equivalent. Use an arbor press to install the countershaft front bearing flush with the case.
Coat the countershaft tabbed thrust washer with petroleum jelly and install it so that the tab engages the corresponding depression in the case.
Turn the transmission case on its end and install the countershaft in the front bearing bore.
Install the countershaft rear bearing spacer (32).
CAUTION: The protector sleeve tool must be used to provide clearance for the needle bearings between the countershaft shoulder and bearing bore.
Coat the countershaft rear bearing with petroleum jelly and install it with Installation Tool J-29895 and Protector Sleeve Tool J-33032.
NOTE: When correctly installed with Tools J-33032 and J-29895, the countershaft rear bearing will extend 3 mm (0.125 in.) beyond the case surface.
Position the reverse idler gear (35) in the case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft (34) from the rear of the case. Install the retaining roll pin (33) in the shaft.
Coat the fifth-reverse gear shift lever pivot pin bolt threads with RTV sealant: Install the fifth-reverse gear shift ever (28). Pivot pin bolt and C-clip retainer. Erisute that the reverse gear shift lever fork is engaged with the reverse idler gear. Tighten the shift lever pivot pin bolt with 58 Nm (43 ft-lbs) torque.
Install the assembled output shaft in the transmission case.
Install the clutch shaft front bearing on the dutch shaft with Tool J-6133-01 and an arbor press.
Coat the 15 pilot roller bearings (24) with petroleum jelly and install them on the clutch shaft.
Install the thrust bearing (25) and race (26) on the clutch shaft.
Install the output shaft rear bearing race cap.
Install the fourth gear blocking ring on the output shaft.
Position the clutch shaft in the case and engage it in the third-fourth gear synchronizer sleeve and blocking ring.
Install a replacement oil seal in the front bearing cap with Tool J-26625.
Install the front bearing race in the front bearing cap. Do not install any shims in the front bearing cap at this time.
Temporarily install the front bearing cap. Do not apply sealant at this time.
Install the fifth driven gear (19) and retaining snap ring (18) on the rear of the output shaft (20).
Insert the fifth-reverse gear shift rail through the opening in the rear of the case and install it in the fifth-reverse gear shift lever. Rotate the rail (27) during installation to simplify engagement with the lever.
Install the countershaft rear bearing spacer (30) and retaining snap ring (29).
Install the fifth gear on the countershaft.
Install the fifth-reverse gear shift lever over-center link spring (B).
Assemble the fifth gear synchronizer sleeve, insert springs and insert retainer. Use the reference marks scribed during disassembly for alignment.
Install the plastic inserts in the notches on each side of the fifth gear shift fork.
Position the assembled fifth gear synchronizer sleeve on the fifth gear shift fork (13) and slide it onto the countershaft (17) and the fifth-reverse gear shift rail.
NOTE: Ensure that the roll pin hole in the fifth-reverse gear shift rail and fifth gear shift fork are aligned.
CAUTION: Place a wood block (11) under the fifth gear shift fork during roll pin installation to prevent damage to the fifth-reverse gear shift rail.
Place the assembled fifth-reverse gear shift rail and shift fork on a block of wood (11) and install the retaining roll pin (10).
Install the thrust bearing race adjacent to the fifth gear synchronizer hub and install the retaining snap ring (12).
Install the needle-type thrust bearing (9) against the thrust bearing race on the countershaft. Coat both the thrust bearing and race with petroleum jelly.
Install the lipped thrust race (8) over the needle-type thrust bearing. Install the plastic funnel (7) in the hole at the end of the countershaft gear.
Temporarily install the adapter housing. Do not seal the housing and the case or tighten the bolts with the final torque at this time.
Position the transmission case on its end. Attach a dial indicator (J-8001) on the adapter housing with the indicator stylus located on the end of the output shaft.
Rotate the clutch and output shafts and zero the dial indicator pointer.
Pull upward on the output shaft until the output shaft end play is eliminated. Note the end play dimension indicated on the dial indicator
NOTE: To completely eliminate the output shaft and clutch shaft end play, the bearings must be preloaded from 0.03 to 0.13 mm (0.001 to 0.005 in.).
Select a shim pack that is 0.03 to 0.13 mm (0.001 to 0.005 in.) thicker than the end play measured above.
Place the transmission horizontally on a workbench and remove the front bearing cap and front bearing race.
Add shims to the bearing cap to obtain the necessary preload and install the bearing race in the cap.
Apply a bead of RTV sealant on the case mating surface for the cap. Install the front bearing cap. Ensure the reference marks scribed during disassembly are aligned. Tighten the retaining bolts with 18 Nm (13 ft-lbs) torque.
Measure the end play. There must be no end play.
Remove the dial indicator from the adapter housing.
Remove the adapter housing and install the adapter housing rear seal with Tool J-29184.
Move the shift forks on the transmission cover and the synchronizer rings inside the transmission case to the neutral position.
Apply a bead of RTV sealant to the cover mating surface on the transmission case.
Lower the cover, at a slightly off center attitude, onto the transmission case while aligning the shift forks and synchronizer sleeves. Center the cover on the case to engage the reverse gear lever fork and install the two dowel bolts in the cover.
Install the remaining bolts and tighten all the cover bolts with 12 Nm (9 ft-lbs) torque.
NOTE: The offset lever-to-shift rail roll pin hole should be in a vertical position at this time.
Apply a bead of RTV sealant on the adapter housing-to-transmission case mating surface.
Install the adapter housing over the output shaft and the shift rail at a position where the shift rail just enters the shift cover opening. Install the detent spring (6) in the offset lever (2). Place the detent ball (5) in the neutral guide plate detent. Apply force on the detent ball with the detent spring and offset lever and slide the offset lever onto the shift rail.
Seat the adapter housing on the transmission case.
NOTE: The offset lever and shift rail roll pin holes should be aligned and in the vertical position at this time.
Install and tighten the adapter housing retaining bolts with 27 Nm (20 ft-lbs) torque.
Install the roll pin (1) in the offset lever (2) and shift rail (3).
Install the damper sleeve in the offset lever.
Coat the backup lamp switch threads with RTV sealant, install the switch in the transmission case and tighten with 20 Nm (15 ft-lbs) torque.
Install the drain bolt.