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21-1 8
TRANSMISSION-3-SPEED
MANUAL
gear,
before the spreader spring is installed (Fig. 37).
If
the
synchronizer "float" is below .050 inch, ma-
terial should be removed from the ends of all six syn-
chronizer pins (an equal amount) until the synchro-
nizer "float" is above the .050 inch dimension.
(4) Install the synchronizer clutch gear on the main-
shaft. Install the synchronizer clutch gear snap ring in
the mainshaft groove. Make certain the ring is bot-
tomed all the way around in the groove.
(5) Measure clearance between the clutch gear and
2nd speed gear. Clearance should be .004 to .014
inch. End play in excess of .014 inch may cause 2nd
speed gear "Jump out."
(6) A-903:
Install the 2nd and direct fork in the
lever shaft with the offset toward rear of the trans-
mission.
A-745:
Install the 2nd and direct fork in the lever
shaft.
Hold the synchronizer clutch gear sleeve and two
outer rings together, with pins properly entered in
the holes in the clutch gear sleeve. Engage the 2nd
and direct fork with the clutch gear sleeve.
(7) While holding the synchronizer parts and fork
in position, slide the mainshaft forward, entering
the synchronizer clutch gear into the clutch gear
sleeve and at the same time entering the mainshaft
rear bearing in the case bore.
If synchronizer parts
are not positioned as described in steps
6 and 7, it
will not be possible to place them in position after
mainshaft i s fully in position, due to interference
with countershaft gear.
(8) While continuing to hold the synchronizer parts
in position, tap the mainshaft forward until the rear
bearing bottoms in the case bore.
(9) Install the mainshaft rear bearing snap ring in
place in the groove in the case bore.
This snap ring
is a select fit.
Drive Pinion
(1) Slide the oil slinger (if removed) over the pin-
ion shaft and down against the gear (Fig. 23).
(2)
Slide the bearing over the pinion shaft (snap
ring groove away from the gear end), then seat on the
shaft, using an arbor press.
A-903:
Install the keyed washer between the bear-
ing and the retaining snap ring.
(3) Secure the bearing and washer with the selected
thickness snap ring. Four snap rings are available to
eliminate end play (same thickness as clutch gear
and mainshaft snap rings).
Be sure the snap ring is properly seated. If the large
snap ring around the bearing was removed, install at
this time.
(4) Place the pinion shaft in a vise (with soft jaws),
then install bearing rollers in the cavity of the shaft.
14 rollers for the A-903 transmission and 15 rollers for
the A-745 transmission. Coat the bearing rollers with
heavy grease, then install the bearing retaining ring
in its groove.
(5) Install the third gear inner stop ring, (Fig. 24
or 25) in the third gear outer stop ring. Guide the
drive pinion through the front of the case and en-
gage the inner stop ring with the clutch teeth, then
seat the pinion bearing. The pinion shaft bearing is
fully seated when the snap ring is in full contact
with the case.
CAUTION: When installing the drive pinion in the
A-903 transmission, be careful not to bend the "anti-
backlash" plate teeth against the teeth on the coun-
tershaft gear.
(6)
Install a new seal in the pinion bearing retain-
er,
using Tool C-3789.
(7) Using a new gasket, install the drive pinion and
retainer in the case. Install attaching bolts and tighten
to 35 foot-pounds torque.
Extension Housing
(1)
A-903:
If the extension housing bushing requires
replacement, drive the bushing out of the housing
with Tool (2-3755. Install new bushing using Tool
C-3751, as the tool is being removed, it burnishes the
bushing to the correct size.
(2)
A-903:
Install the extension housing oil seal
using Tool C-3754. Place seal protector Tool
C-3768
on the mainshaft splines to protect the seal while in-
stalling the extension housing. Lightly lubricate the
gasket surface of the case and the seal protector tool.
(3)
A-745:
Install the bearing and a new seal in the
extension housing using Tool (2-3837.
(4) Slide the extension housing and gasket over the
mainshaft and down against the case, at the same
time guiding the shaft into the oil seal. Install at-
taching bolts and tighten to
50
foot-pounds torque.
(5) Install the flange assembly, and secure with a
new washer and nut. Tighten the nut
to
175 foot
pounds torque while holding the flange with Tool
(6)
Lightly lubricate the cover gasket surface, then
install gasket and cover. Install the attaching bolts
and tighten to 144 inch-pounds torque.
(7) Install the drain plug and back-up light switch
(if
so equipped) and tighten securely.
(8) Refill the transmission with Automatic Trans-
mission Fluid, Type "A," Suffix "A." Install filler plug
and tighten securely.
lnstullution
On the 121V2 inch wheelbase Plymouth Station
Wagons, refer to Group
2,
"Torsion Bar Rubber Iso-
lator" for installation of the torsion bar rear anchor
crossmember and rubber isolators.
Place a small amount of short fibre wheel bearing
lubricant around the inner end of the main drive pin-
ion shaft pilot bushing in the flywheel and on the
pinion bearing retainer release bearing sleeve area.
C-3281.
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