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MANUAL TRANSMISSION
21 - 11
good condition, i f t h e grooves are w o r n , or damaged,
replace t h e shaft. D o not a t t e m p t t o reuse i t .
SNAP
RING GROVE
THRUST
FACE
SNAP
RING GROOVE
J
7
AAAINSHAFT
\»»»»]
7
SNAP
RING GROOVE
RH91
Fig. 13 Mainshaft Snap Ring And Thrust Surfaces
Bearings/Thrust Washers
Inspect t h e roller, b a l l a n d needle bearings. Be
sure t h e bearings are clean a n d d r y before inspec-
t i o n . Replace a n y b e a r i n g t h a t is r o u g h , corroded,
b r i n n e l l e d , galled, w o r n , o r scored. Lubricate t h e
bearings w i t h engine o i l after inspection.
Check condition o f t h e countershaft gear t h r u s t
washers, replace t h e washers i f cracked, worn, or
damaged i n any way.
Gears
Inspect a l l of t h e transmission gears for worn, bro-
k e n , chipped teeth. Replace gears as necessary. M i -
nor nicks or b u r r s o n gear t e e t h can be dressed off
w i t h a n oilstone.
Inspect the teeth and splines on the drive pinion. I f
either are excessively w o r n , o r are broken or chipped,
a new p i n i o n should be i n s t a l l e d . I f t h e o i l seal con-
tact area on the p i n i o n is p i t t e d , rusted, or scratched,
a new p i n i o n should be i n s t a l l e d to preserve the o i l
seal and prevent c l u t c h c o n t a m i n a t i o n .
Levers/Forks/Gearshift Housing
Inspect t h e interlock levers, shift forks, operating
levers and shafts. Be sure these parts are free of dis-
t o r t i o n , or cracks a t the detent and clearance notches
a n d a t each end o f levers. Check the shift forks for
wear on the pads and shafts. Replace components ex-
h i b i t i n g damage or excessive wear.
Inspect the shaft bores i n t h e gearshift housing. Be
sure the bores are free o f b u r r s . The seal surfaces o f
t h e housing must be i n good condition and not dam-
aged i n a n y way. Verify t h a t t h e operating lever
shafts f i t smoothly and are bind-free.
Synchronizer Components
Inspect the splines and t e e t h o n t h e synchronizer
clutch gears and sleeves. I f there is evidence of chip-
p i n g or excessively w o r n t e e t h , i n s t a l l new parts a t
reassembly. Be sure each c l u t c h sleeve slides easily
on the clutch gear.
Synchronizer springs should be i n place w i t h t h e
t a n g inside t h e cavity o f one s t r u t and should n o t
show signs o f interference
w i t h t h e polished gear
cones or inside diameters o f t h e clutch gears.
Inspect the stop r i n g s for cracks and wear. I f rings
are cracked
or show
signs
o f extreme
wear o n
threaded bore, i n s t a l l new r i n g s a t reassembly. Test
new rings for good f i t o n gear cones w i t h m i n i m u m
wobble. Check synchronizer s t r u t s for wear or break-
age.
Synchronizers a r e t o be serviced as a n assembly.
Except for stop r i n g s , synchronizer parts should not
be interchanged.
TRANSMISSION ASSEMBLY
REVERSE
GEAR/SHAFT/LEVER/FORK
INSTALLATION
(1) I n s t a l l reverse lever i n case bore.
(2) Lubricate n e w lever shaft o i l seal w i t h petro-
l e u m j e l l y and i n s t a l l seal i n and seal retainer i n
case bore.
(3) Insert reverse idler gear shaft i n end o f case.
Tap idler shaft i n t o case far enough to p e r m i t i n s t a l -
l a t i o n o f reverse i d l e r gear o n shaft.
(4) A l i g n reverse lever i n slot o f reverse idler gear
and slide gear onto shaft. B e s u r e l e v e r s l o t i n g e a r
i s t o w a r d r e a r o f case.
(5) A l i g n woodruff key slots i n case a n d idler gear
shaft and t a p shaft 3/4 o f w a y i n t o case. T h e n insert
woodruff k e y i n shaft a n d t a p shaft i n w a r d u n t i l
shaft is flush w i t h case surface.
(6) I n s t a l l backup l a m p s w i t c h and gasket. T i g h t e n
switch to 20 N»m (15 ft-lbs) torque.
COUNTERSHAFT
GEAR/DRIVE
PINION
INSTALLATION
(1) Coat bore of countershaft gear a t each end w i t h
petroleum j e l l y and i n s t a l l bearing spacer and arbor
tool C-3938 i n bore. Be sure to center spacer and ar-
bor i n gear as shown (Fig. 14).
COUNTERSHAFT
GEAR
SPECIAL TOOL
C-3938 ARBOR
RH95
Fig. 14 Arbor Tool Centered In Countershaft Gear
(2) Coat t h e countershaft needle bearing rollers,
spacers and t h r u s t washers w i t h petroleum j e l l y .
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