Assembly
ASSEMBLYPrecaution
1. All 0-rings and gaskets must be replaced with new ones included in the overhaul kit.
2. Verify that all parts are completely cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil.
4 After assembly, shift the transmission to each position, and check for smooth and correct operation.
Control Case
1. Install the 5th/reverse cam lockout plate.
2. Install the 1st/2nd and 3rd/4th interlock pins.
3. Install the shift rods,
4. Install the rubber plugs into the service bores.
5. Install the park/neutral position switch.
6. Install the back-up light switch.
7. Install the dust cover,
5th/reverse cam lockout plate
Install the 5th/reverse cam lockout plate and bolts.
Tightening torque: 8-10 N.m {0.8-O.9 kgf.m, 6-7 ft.lbf}
Interlock pins
Install the large and small pins in their original positions.
3rd/4th shift rods
1. Position the shift rod into the control case.
2. Position the detent ball and spring into the control case spring seats.
3. Compress the detent ball and spring assembly and push the shift rod into position over the detent ball.
4. Engage the 3rd/4th shift fork with the shift rod.
5. Position the friction device and spring into the control case spring seats.
6. Compress the friction device and spring assembly and push the shift rod into position over the friction device.
7. Install the 3rd/4th shift gate.
8. Install the 3rd/4th shift fork spring interlock pins.
1st/2nd shift rods
1. Position the shift rod into the control case.
2. Position the detent ball and spring into the control case spring seats.
3. Compress the detent ball and spring assembly and push the shift rod into position over the detent ball.
4. Engage the 1st/2nd shift fork with the shift rod.
5. Position the friction device and spring into the control case spring seats.
6. Compress the friction device and spring assembly and push the shift rod into position over the friction device.
7. Install the 1st/2nd shift gate.
8. Install the 1st/2nd shift fork spring interlock pins.
5th/reverse shift rods
1. Position the shift rod into control case.
2. Position the detent ball and spring into the control case spring seats.
3. Compress the detent ball and spring assembly and push the shift rod into position over the detent ball.
4. Engage the 5th/reverse shift fork with the shift rod.
5. Install the 5th/reverse shift gate.
6. Install the 5th/reverse shift fork spring interlock pins.
Dust cover
Install the dust cover.
Tightening torque: 8-11 N.m {O.8-1.1 kgf.m, 6-8ft.lbf}
Back-up light switch
Apply sealant to the threads and install.
Tightening torque: 25-35 N.m {2.5-3.4 kgf.m, 18-25 ft.lbf}
Park/neutral position switch
Apply sealant to the threads and install.
Tightening torque: 25-35 N.m {2.5-3.4 kgf.m, 18-25 ft.lbf}
Secondary Shaft Parts
Assemble in the order shown in the figure.
1. 2nd gear needle bearing
2. 2nd gear
3. Synchronizer ring (2nd)
4. Clutch hub and sleeve assembly (1st/2nd)
5. Synchronizer ring (1st)
6. 1st gear needle bearing
7. 1st gear
8. 1st gear sleeve
9. Center bearing-inner
10. Center bearing-outer race
11. 3rd gear needle bearing
12. 3rd gear
13. Synchronizer ring (3rd)
14. Clutch hub and sleeve assembly (3rd/4th)
15. Spacer
16. Needle bearing
17. Retaining ring
18. Roller bearing
Secondary shaft
Press the 1st and 2nd gear components into position using the SSTs and Bearing Cone Replacer T53T- 4621-B, or equivalent.
Note: When installing the clutch hub and sleeve (1st/2nd), make sure that the smaller width of the sleeve faces the 2nd gear side. The reference marks face the rear of the transmission.
Center bearing
Press the center bearing onto the secondary shaft using the SSTs and sleeve.
Note: Fabricate a sleeve where the inside diameter is large enough to fit over the secondary shaft but small enough to engage the inner bearing race.
Note: SST Numbers: 49 1243 465A and 49 UN17 101 Shaft Collar and 49 H027 002 Bearing Plate.
Clutch hub and sleeve assembly (3rd/4th)
1. Mate the clutch hub synchronizer key groove with the slants on the inner surface of the clutch hub sleeve.
Note: The turned edge of the clutch hub sleeve should face toward 4th gear.
2. Install the longer flange on the clutch hub sleeve toward the 3rd gear side.
Note: The 3rd gear synchronizer ring has three teeth cut out 120° apart from each other. Directly adjacent to one side of the missing teeth two teeth have been bridged together.
Note: The front and rear sides of the clutch hub may appear to be similar. Install the clutch hub with the chamfer facing 4th gear.
3. Measure the 3rd/4th clutch hub end play with the original retaining ring installed.
Standard end play: O.OO-O.O5mm {O.OO-O.0020 in}
4. If the end play is not as specified, select the proper retaining ring.
Retaining Ring Select Chart
Assembly
1. Assemble in the order shown in the figure.
2. Install the speedometer drive gear.
3. Install the extension housing, referring to Assembly Note.
4. Install the control case, referring to Assembly Note.
5. Add the specified amount and type of transmission oil.
1. Oil trough
2. Oil trough bolt
3. Countershaft assembly
4. Secondary shaft center bearing outer race
5. Primary shaft
6. Secondary shaft assembly
7. Secondary shaft center bearing outer race
8. Center bearing cover
9. Countershaft front bearing
10. Front bearing cover
11. 5th gear ball
12. 5th gear sleeve
13. Countershaft 5th gear
14. 5th gear needle bearing
15. Secondary shaft 5th gear
16. Countershaft lever.
17. Spring
18. Detent Ball
19. Clutch hub and sleeve (5th/reverse)
20. Synchronizer ring (5th)
21. Shift fork assembly
22. Shift rod bolt
23. Split washer
24. Thrust washer
25. Synchronizer ring (reverse)
26. Needle bearings
27. Countershaft reverse gear
28. Thrust washer
29. Reverse idler gear
30. Reverse idler gear bolt
31. Secondary shaft sleeve
32. Secondary shaft reverse gear
33. Secondary shaft rear bearing
34. Countershaft rear bearing
35. Locknut (secondary shaft)
36. Locknut (countershaft)
Secondary shaft center bearing outer race Use a brass drift to install the outer race.
Note: Make sure that the outer race is squarely positioned in the bore.
Primary shaft
1. Press the primary shaft bearing onto the primary shaft using Bearing Cone Remover 171 P-4621 -B, or equivalent and the SST.
2. Install the plastic scoop ring
Note: Manually rotate the scoop ring clockwise to make sure that the main drive gear oil holes properly engage the scoop ring. A click should be heard as the scoop ring notches align with the primary shaft oil holes.
Front bearing cover
1. If removed, install the front cover oil seal using the SST.
2. Measure height A of the primary shaft bearing outer race.
3. Measure depth B of the front cover outer race bore.
4. Measure depth C of the countershaft front bearing race.
5. Measure depth D of the front cover outer race bore.
6. Select an adjustment shim(s) to maintain end play within the specified limits.
B-A + adjustment shim: O.05-O.15mm {0.002-0.006 in}
C+D - adjustment shim: 0.15-O.25mm {0.00-0.010 in}
Secondary Shaft Shim Select Chart
Countershaft Spacer Select Chart
7. Position the bearing shim and baffle plate into the front cover (install the shim with the groove showing).
8. Install the spacer in the transmission countershaft front bearing bore.
9. Tape the primary shaft splines along their entire length.
1O. Apply a 1/8 in bead of appropriate sealant to the front cover and bolt threads.
11. Install front cover.
Tightening torque: 16-22 N.m {1.7-2.2 kgf.m, 12-16 ft.lbf}
Note: Make sure that the bolt heads are marked with a "6".
Center bearing cover
Install the center bearing cover with the reference arrow pointing up
Tightening torque: 18-26 N.m {1.8-2.6 kgf.m 13-19 ft.lbf}
Note: Make sure that all bolt heads are marked with an "8" Countershaft lever assembly Install the countershaft lever assembly.
Tightening torque: 8-1O N.m {O.8-O.9 kgf.m, 6-7 ft.lbf}
Shift fork assembly
1. Install the spring and detent ball into the shift fork.
2. Depress the detent ball and insert the shift rail.
3. Locate the neutral position.
4. Install the 5th/reverse clutch hub and sleeve, and the 5th gear synchronizer ring on the shift fork assembly.
Note: The reference mark on the synchronizer sleeve must be installed toward the reverse gear side.
5. Install the shift fork assembly on the countershaft.
6. Apply sealant to the threads of shift fork assembly boll.
Tightening torque: 20-30 N.m {2.2-3.0 kgf.m, 16-22 ft.lbf}
Split washer
1. Measure the countershaft reverse gear end play if the original split washers are not being installed.
Standard end play: O.25-0.35mm {O.O1O-.O14 in}
2. If the end play is not as specified, select the proper split washer.
Split Washer Select Chart
Thrust washer
1. While pushing the thrust washer against the shoulder on the countershaft, measure the clearance between the thrust washer and the countershaft reverse gear.
Clearance: 0.25-O.35mm {0.01 0-0.014 in}
2. If the clearance is not as specified, select the proper thrust washer.
Thrust Washer Select Chart
Reverse idler gear
1. Install the thrust washer onto the reverse idler gear.
Note: Make sure the tabs on the thrust washer mates with the groove on the reverse idler shaft.
2. Install the needle bearings, idler gear, and spacer.
3. Install the original retaining ring.
4. Measure the end play between the retaining ring and the reverse idler gear.
End play: O.1-0.2mm {O.0039-O.0078 in}
5. If the end play is not as specified, select the proper retaining ring.
Reverse Idler Gear Retaining Ring Select Chart
Countershaft rear bearing
Temporarily install a suitable spacer (inner bore larger than 21mm {0.82 in} outer bore smaller than 36mm {1.41 in}, 15-2Omm {0.59-0.78 in} overall length) in place of the countershaft bearing.
Secondary shaft rear bearing
Install the bearing using the SST, Shaft Adapter T75L- 7025-M (4x4 only), Gear Installing Spacer 188T-7025-E, or equivalents.
Locknuts
Caution: Do not reuse the removed locknuts.
1. Remove the temporary spacer from the countershaft.
2. Install the countershaft rear bearing.
3. Lock the transmission into 1st and 3rd gears.
4. Install the secondary shaft locknut.
Tightening torque: 216-274 N.m {22-27 kgf.m, 159-202 ft.lbf}
5. Install the countershaft locknut.
Tightening torque: 128-196 N.m {13.0-19.8 kgf.m, 94-144 ft.lbf}
6. Stake the locknuts.
Oil passage
Install the oil passage.
Tightening torque: 8-1O N.m {O.8-1.O kgf.m, 6-7 ft.lbf}
Speedometer drive gear
The speedometer drive gear contains detents into which the steel drive ball can be installed. The steel drive ball can be installed into any of the three detents.
Extension housing
1. Install the extension housing.
Tightening torque: 32-46 N.m {3.3-4.5 kgf.m, 24-33 ft.lbf}
2. install the extension housing rear oil seal using the Extension Housing Seal Replacer T61 L-7657-A, or equivalent.
Note: Make sure that the oil seal drain hole faces downward. The extension housing bushing cannot be serviced. If the bushing requires service, the extension housing must be replaced. (4x2 only)
Control case
Install the control case.
Tightening torque: 16-22 N.m {1.7-2.2 kgf.m, 12-16 ft.lbf}
Note: Do not apply sealant to the control case or transmission mating surfaces.
Drain plug
Install the drain plug.
Tightening torque: 40-58 N.m {4.1-5.7 kgf.m, 30-42 ft.lbf}