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MANUAL TRANSMISSION
21 - 41
MAINSHAFT
(1) Place mainshaft i n soft-jawed vise w i t h rear end
up.
(2) I n s t a l l first and reverse speed gear. Be sure the
two spline springs ( i f used) a r e i n place inside gear
as i t is placed on shaft.
(3) M o u n t mainshaft i n vise w i t h forward end o f
shaft facing up. Use protective j a w s t o avoid damag-
i n g shaft surfaces.
(4) I n s t a l l second gear synchronizer s p r i n g and syn-
chronizer on gear. Secure w i t h snap
ring
m a k i n g
sure t h a t snap r i n g tangs are away f r o m gear.
(5) Slide second speed gear onto f r o n t o f o u t p u t
shaft m a k i n g sure t h a t synchronizer is t o w a r d rear.
Secure gear t o shaft w i t h two-piece lock r i n g . I n s t a l l
t h i r d speed gear.
(6) I n s t a l l shim(s) between t h i r d speed gear and
t h i r d and f o u r t h speed synchronizer stop r i n g . Refer
to end play measurement a t disassembly to deter-
m i n e s h i m thickness needed for correct end play of
1.27 - 1.78 m m (.050 to .070 inch). Exact determina-
t i o n of end play m u s t be made after complete assem-
b l y o f mainshaft and m a i n d r i v e p i n i o n is installed
i n the transmission case.
REVERSE
IDLER
GEAR
No gear assembly required. I f no longer service-
able, replace as a n assembly complete w i t h i n t e g r a l
bearings.
DRIVE PINION AND BEARING
RETAINER
(1) Coat roller bearings w i t h petroleum j e l l y (to
hold rollers i n place) and i n s e r t i n pocket o f drive
p i n i o n gear.
(2) I n s t a l l washer and snap r i n g .
(3) Press a new o i l seal i n t o place i n bearing re-
tainer. Make sure l i p of seal i s t o w a r d m o u n t i n g sur-
face (rearward).
COVER AND SHIFT FORKS
(FIG. 6)
(1) Assemble s p r i n g on reverse gear plunger and
hold i t i n reverse shift gate. Compress i t i n gate and
i n s t a l l r e t a i n i n g clip.
(2) Enter reverse shift r a i l i n cover and place de-
t e n t spring and b a l l i n position. Depress b a l l a n d
slide r a i l over i t .
(3) I n s t a l l gate and fork on r a i l . I n s t a l l a new r o l l
p i n i n gate and i n fork.
(4) Place reverse fork i n n e u t r a l position.
(5) I n s t a l l the two interlock plungers i n t h e i r bores.
(6) Insert the interlock p i n i n t h e t h i r d and f o u r t h
speed shift r a i l . I n s t a l l r a i l i n t h e same manner as
reverse shift r a i l .
(7) I n s t a l l first and second speed shift r a i l i n the
same manner m a k i n g sure t h e i n t e r l o c k plunger is
i n place.
(8) Check interlocks b y s h i f t i n g reverse shift r a i l
into reverse position. I t should n o t be possible t o
shift the other shift r a i l s w h e n t h i s r a i l is shifted.
(9) I f shift lever is t o be installed a t this point l u -
bricate spherical b a l l seat and place cap i n place.
(10) I n s t a l l back-up lamp switch.
(11) I n s t a l l n e w expansion plugs i n bores o f r a i l
holes.
(12) I n s t a l l r a i l interlock hole plug.
TRANSMISSION ASSEMBLY
COUNTERSHAFT
(1) Press front roller bearing into case u n t i l cage is
flush w i t h front of case. Lubricate roller bearings
w i t h petroleum j e l l y .
(2) Place transmission w i t h front of case facing
down. I f uncaged bearings are reused, hold loose r o l l -
ers i n place i n cap w i t h l i g h t f i l m of grease (not re-
quired w i t h caged type).
(3) Lower countershaft assembly into case placing
t h r u s t washer tangs i n slots i n case, and i n s e r t i n g
front end of shaft into bearing.
(4) Place roller t h r u s t bearing and race on rear end
of countershaft, h o l d i n g i n place w i t h l i g h t coating of
grease.
(5) W h i l e holding gear assembly i n alignment i n -
stall rear bearing retainer gasket, retainer and bear-
i n g assembly. I n s t a l l and t i g h t e n cap screws.
REVERSE
IDLER
ASSEMBLY
(1) Position reverse gear and bearing assembly i n
case.
(2) A l i g n idler shaft so lock plate groove i n shaft is
i n proper alignment t o i n s t a l l lock plate.
(3) Tap shaft into case far enough to start reverse
gear.
(4)
W h i l e
holding
gear
i n position, t a p shaft
t h r o u g h case and gear.
(5) I n s t a l l lock plate, washer, and cap screw.
(6) M a k e sure gear t u r n s freely on shaft.
MAINSHAFT
AND DRIVE
PINION
(1) Lower rear end o f pre-assembled mainshaft into
case h o l d i n g first speed gear on shaft and maneuver
shaft t h r o u g h rear bearing opening.
(2) W i t h shaft assembly moved to rear of case, be
sure t h i r d and f o u r t h speed synchronizer and prese-
lected shims r e m a i n i n position.
(3) I n s t a l l roller type t h r u s t bearing.
(4) Place a wooden block between front of case and
front o f mainshaft.
(5) I n s t a l l rear bearing on mainshaft by carefully
d r i v i n g bearing onto shaft and into case (snap r i n g
flush against case) using a suitable sleeve against i n -
ner race o f bearing.
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