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11. Check countershaft gear end play by inserting a
feeler gauge between the rear thrust washers as
shown in Figure 18. End play should range be-
tween .006" and .016".
12. After checking for proper end play, enter the
dummy shaft in front of transmission case and
carefully tap out the countershaf t through rear of
case. After the countershaft has been removed,
lower the cluster gear with dummy shaft to bot-
tom of case.
13. Install the reverse idler gear in the case (long hub
of gear toward front of case) and drive the reverse
idler gear shaft in from rear of case.
NOTE: Before fully installing the shaft, make sure
the slot in shaft is properly aligned with the slot in
countershaft so that the lock plate will seat prop-
erly.
14. Check idler gear end play; should be .003" to .010".
15. Install the second and high shift fork in the second
and high shifter shaft.
16. Install the transmission mainshaft bearing and oil
slinger (lip to inside) on the mainshaft an d in the
overdrive adapter and install the large retaining
snap ring.
NOTE: The s e snap rings are furnished in four
thicknesses, select the ring of the proper thickness.
17. Install the low and reverse sliding gear (shifter
collar of gear to rear of transmission).
18. Install the mainshaft second speed gear assembly
on the mainshaft.
19. Assemble the synchronizer clutch hub, shift plate,
shift sleeve, springs and synchronizer rings to-
gether as a unit and install the assembly on the
shaft with long end of the synchronizer clutch hub
to front of transmission.
NOTE: Be sure that marks painted on the syn-
chronizer parts during disassembly are properly
aligned at re-assembly, also that the hooked ends
of the two synchronizer springs engage in the
same shift plate.
OVERDRIVE 102
20. Install the snap ring on front of mainshaft
and check end play by inserting a feeler
gauge between the rear face of the main-
shaft second speed gear where it butts up
against the mainshaft (at ends of mainshaf t
spiral splines). This end play should be from
.003" to .016". Excessive end play at this
point can only be corrected by installing new
parts.
21. Install new adapter plate to transmission
gasket and install the mainshaft assembly
with the adapter plate; engage the second and
high shifter fork in the shift sleeve, then pull
mainshaft towards side of case sufficiently to
install the low and reverse shifter fork; offset
to rear.
22. Install main drive gear bearing on the main
drive gear using Driver J-2995-1, Figure 16,
an d install the snap ring to retain the bearing
on the main drive gear. Make sure the proper
thickness snap ring is used.
NOTE: The main drive gear snap rings are
furnished in the following thickness: .087",
.090", .093", .096" and .103".
The main drive gear bearing snap rings are
furnished in .073" and .076" thickness.
23. Coat inside of mainshaft drive gear and
mainshaft front rollers with viscous grease
and assemble rollers in position in the gear.
24. In stall the mainshaft drive gear and bearing
assembly into the front bore of transmission,
tapping outer race of bearing with a rawhide
hammer until the snap ring in the outer race
is flush with front of case.
25. While holding pilot end of mainshaft en-
gaged in pocket bearing of the main drive
gear, carefully tip the complete transmission
so that the transmission will rest on the gas-
ket face of the transmission cover opening.
This will allow the countershaft gear to align
with the countershaft holes in the case.
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