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TRANSMlSSlON4-SPEED MANUAL
21 -27
THRUST WASHER
TANG
COUNTER SHAFT
GEAR
\THRUST WASHER
TANG
6 4 x
754
Fig. 55-Countershaft
Gear and Arbor Assembly
thrust washers. Coat thrustwashers with heavy grease
and install them over the arbor with the tang side to-
ward the case boss (Fig. 55).
(4) Install the countershaft gear assembly into the
case (Fig. 54). Allow the gear assembly to rest on the
bottom of the case. (Be sure the thrustwashers stay
in position.)
(5) Slide the bearing oil slinger over the main drive
pinion shaft, then press the main drive pinion bear-
ing on the pinion shaft. Be sure the outer snap ring
groove is toward the front (Fig. 56). Seat the bearing
fully against the shoulder on the gear.
(6) Install a new inner snap ring into the groove
to retain the bearing. Be sure the snap ring is seated.
(7)
Place the pinion shaft in a vise (with soft jaws),
then install 16 bearing rollers in the cavity of the
shaft. Coat the bearing rollers with heavy grease, then
install the bearing retaining snap ring in its groove.
(8) Install the main drive pinion and bearing in the
case and into position in the front bore. Tap lightly
into place, using a plastic hammer. Install the outer
snap ring in the bearing groove.
(9) Using Tool C-3789, install a new oil seal in the
retainer bore. Install the main drive pinion bearing re-
tainer and gasket. Install the attaching bolts and
tighten to 35 foot-pounds torque.
(10) Start the countershaft in its bore at the rear
of the case. Raise the countershaft gear until the
teeth mesh with the main drive pinion gear. (Be sure
the thrust washers remain in position on the ends
of the arbor and the tangs aligned with the slots in
the case.)
225
and
273
cubic inch engine equipped vehicles:
Do
not install the countershaft at this time as addi-
tional clearance is required to install the mainshaft
assembly.
(11) Align the countershaft arbor with the bores
in
the case, then drive
or
press the countershaft into the
gear. Install the woodruff key. Continue to press the
BEARING
MAIN DRIVE
PIPION
SNAP
RING
(OUTER)
TOWARD THE
FRONT
\
ROLLER
BEARINGS (16)
6 4 x
755
Fig. 5 6 - M a i n Drive Pinion and Bearing Assembly
shaft into the case until the end of the shaft is flush
with the rear face of the case. Remove arbor Tool
C-3938.
Reverse Gear, Lever and Fork
The following step need only be done if the reverse
shaft was removed because of oil leak.
(1) Install a new oil seal on the reverse gearshift
lever shaft. Coat the lever shaft with multi-purpose
grease, then carefully install the lever shaft into
bore in the case (Fig. 53). Install the reverse fork in
the lever. Fill the recess next to the shaft with multi-
purpose grease, then install the operating lever (Fig.
39). Install a flatwasher, lockwasher and nut. Tighten
nut securely.
(2)
Install the reverse shift detent ball and spring.
Install the reverse detent ball spring retainer gasket
and retainer. Tighten securely.
(3) Position the reverse slider gearshaft in position
in the end of the case, and drive in far enough to po-
sition the reverse slider gear on the protruding end
of the shaft with the shift slot toward the rear
(Fig. 52). At the same time, engage the slot with the
reverse shift fork.
(4) With the reverse slider gear correctly posi-
tioned, drive the reverse gear shaft into the case far
enough to be able to install the woodruff key. Drive
the shaft into position, flush with the end of the case
(Fig. 52).
( 5 )
Install the back-up light switch and gasket (if
so
equipped), and tighten securely.
Extension Housing and Mainshaft
(1) Slide the second speed gear over the mainshaft
(synchronizer cone toward the rear) and down into
position against the shoulder on the shaft (Fig. 48).
(2)
Slide the first and second clutch sleeve gear
as-
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