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21 - 38
MANUAL TRANSMISSION
FEELER
R H 1 9 6
Fig. 4 Measuring Synchronizer End Play
(2) Rotate t h e drive p i n i o n gear to a l i g n space i n
pinion gear c l u t c h t e e t h w i t h countershaft drive gear
teeth. Remove drive p i n i o n gear a n d b a l l bearing
from transmission. P u l l on p i n i o n shaft a n d tap face
of case w i t h brass h a m m e r to remove.
(3) Remove snap r i n g , washer,
a n d p i l o t roller
bearings from recess i n drive p i n i o n gear.
MAINSHAFT
(1) Place a brass d r i f t i n front center o f mainshaft
and drive mainshaft t o rear.
(2) When mainshaft rear bearing has cleared case
remove rear bearing w i t h a suitable puller.
(3) Move mainshaft assembly to rear and t i l t front
of mainshaft up.
(4) Remove roller type t h r u s t bearing.
( 5 ) Remove synchronizer and stop rings separately.
(6) Remove mainshaft assembly.
REVERSE
IDLER
GEAR
(1) Remove reverse idler lock screw and lock plate.
(2) W i t h brass d r i f t held at angle, drive idler shaft
to rear and p u l l shaft.
( 3 ) L i f t reverse i d l e r gear f r o m case.
COUNTERSHAFT
GEAR
(1) I f excessive side play a n d end play are n o t
found and teeth are n o t badly w o r n or chipped, coun-
tershaft gear should n o t require replacement.
How-
ever, i f gear is damaged, remove as follows.
(2) Remove bearing retainer a t rear end o f counter-
shaft. The roller bearing assembly a t rear end o f
shaft remains w i t h retainer.
:
^
(3) T i l t countershaft gear assembly and w o r k out o f
case.
(4) U s i n g a suitable driver, remove front bearings
from case.
COMPONENT DISASSEMBLY (Fig. 5)
MAINSHAFT
(1) Remove clutch gear snap r i n g .
(2) Remove clutch gear, synchronizer outer stop
r i n g t o t h i r d speed gear shim(s), a n d t h i r d speed
gear. .
(3) Remove special split lock r i n g w i t h t w o screw-
drivers. Remove second speed gear and synchronizer.
(4) Remove first and reverse s l i d i n g gear.
REVERSE
IDLER
GEAR
(1) Do not disassemble. I f no longer serviceable re-
place as a n assembly complete w i t h i n t e g r a l bear-
ings.
COVER
AND SHIFT FORKS (FIG. 6)
(1) Cover a n d shift forks should be disassembled
only i f r a i l s , poppets, interlock plungers, springs,
shift forks, or cover itself need replacing.
(2) Remove r o l l p i n from first a n d second speed
shift fork. Remove r o l l p i n f r o m gate i n t h e same
manner. A square type or closely w o u n d s p i r a l easy-
out mounted i n a tap handle i s preferable for t h i s op-
eration.
(3) Push shift r a i l out t h r o u g h the front t o force ex-
pansion p l u g o u t of cover. Cover detent b a l l access
hole i n cover w i t h cloth to prevent b a l l a n d spring
from f l y i n g as r a i l clears hole. Remove r a i l , fork, and
gate.
(4) Remove t h i r d a n d f o u r t h speed r a i l s i n t h e
same manner, then remove reverse r a i l .
( 5 ) Compress reverse gear plunger and remove re-
t a i n i n g clip. Remove plunger and spring from gate.
DRIVE PINION AND BEARING
RETAINER
(1) Remove b a l l bearing f r o m p i n i o n shaft w i t h
suitable tool.
(2) Remove snap r i n g , washer and p i l o t rollers from
gear bore ( i f not previously removed).
(3) Remove pinion shaft seal, w i t h suitable seal re-
mover.
COMPONENT ASSEMBLY (Fig. 5)
Use new expansion plugs, gaskets and seals d u r i n g
overhaul. Lubricate a l l parts w i t h transmission l u -
b r i c a n t before assembly. Use petroleum j e l l y to hold
parts i n place d u r i n g assembly i n s t a l l a t i o n .
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