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21 -28
TRANSMISSIONA-SPEED MANUAL
sembly including 2nd gear stop ring over the main-
shaft (with the shift fork slot toward the front) and
down into position against the second speed gear.
(Be sure the stop ring is indexed with the shift plates.)
Install a new snap ring to secure (Fig.
48).
(3) Slide the low gear stop ring over the shaft and
down into position and index with the shift plates.
(4) Slide the first speed gear (synchronizer cone to-
ward the clutch sleeve gear just installed) over the
mainshaft and down into position against the clutch
sleeve gear.
(5)
Install the mainshaft bearing retaining ring, fol-
lowed by the mainshaft center bearing. Using an ar-
bor and a suitable tool, drive or press the bearing
down into position. Install a new snap ring to secure
(Fig. 47).
(6) Slide the rear bearing over the mainshaft and
drive or press into position.
(7) Install the partially assembled mainshaft into
the extension housing far enough to engage the re-
taining ring in the slot in the extension housing (Fig.
46). Compress the retaining ring and at the same time
seat the mainshaft in the extension housing (Fig. 45).
(Be sure retaining ring is seated all around its slot.)
(8) Slide the third speed gear over the mainshaft
(with the synchronizer cone toward the front) fol-
lowed by the third gear stop ring.
(9) Install the third and fourth speed synchronizer
clutch gear assembly (including sleeve, shift plates
and springs) on the mainshaft (shift fork slot toward
the rear) down against the third speed gear. Be sure
and index the rear stop ring with the clutch gear shift
plates (Fig. 44).
(10)
Install the retaining snap ring (Fig.
44),
then,
using heavy grease, position the front stop ring over
the clutch gear, again indexing the ring slots with the
shift plates (Fig. 4 4 ) .
CAUTION: It is very important that the indexing of
all stop rings and the positioning of the gears and
clutches on the mainshaft
be correct, or the mating
of the extension housing to the case will not be pos-
sible without damage.
(11)
Coat a new extension housing to case gasket
with grease (both sides) then place in position on the
case.
(12) Center the reverse slider gear on its shaft and
move the 3rd and 4th speed clutch sleeve slightly to-
ward the front, then carefully insert the mainshaft
into the case (Fig. 42). Be sure the
3rd
and 4th speed
stop ring is indexed with the shifter plates, and at the
same time align and push in on the extension housing
to bottom it against the gasket and case.
(13) 225
and
273
cubic inch engine equipped vehi-
cles:
Rotate the extension housing to expose the open-
ing for the countershaft. Raise the countershaft gear
into position, then drive or press the countershaft
into the gear, install the woodruff key. Continue to
press the shaft into the case until the end of the
shaft is flush with the rear face of the case. Remove
arbor Tool C-3938.
Rotate the extension housing back into place, align
gasket
if
necessary, install extension housing attach-
ing bolts and tighten securely.
Gearshift Housing and Mechanism
The following
4
steps need only be done if the gear-
shift housing was disassembled previously because
of leaking seals.
(1) Slide the interlock sleeve into position in the
housing (Fig.
41).
Install a new oil seal on each gear
shifter shaft. Coat one of the shafts with multi-pur-
pose grease, then carefully install the shaft in the
shift housing.
Fill
the recess next to the shaft with
multi-purpose grease, then install the operating le-
ver (Fig. 39). Install a flatwasher, lockwasher and nut.
Tighten nut securely.
(2)
Place a detent ball in the sleeve, followed by
the spring and interlock pin. Coat the other gear
shifter shaft with multi-purpose grease and start the
shaft into the housing. Place remaining detent ball on
the spring and compress ball and spring with a small
screwdriver, then push shaft in until seated. Fill
the recess next to the shaft with multi-purpose grease,
then install the operating lever, flatwasher, lock-
washer and nut. Tighten nut securely. Install the
gearshift forks in the gear shifter shafts and position
forks and shifter shafts in neutral position (Fig. 41).
(3) Position the 1st and 2nd, 3rd and 4th clutch
sleeve gears in the neutral position, then using a new
gasket install the shift housing making sure the shift
forks align with grooves in the clutch sleeve gears.
(4)
With shift housing in place, install the retain-
ing bolts finger tight, then shift transmission into re-
verse.
Tighten the two end center alignment bolts
first,
then tighten the other retaining bolts. Test by
shifting in and out of reverse several times mak-
ing sure no interference occurs when shifting into re-
verse.
( 5 )
Install the gearshift control assembly and con-
nect the shift rods (Fig. 38).
(6)
Install the propeller shaft flange on end of the
mainshaft. Install washer and nut, and tighten to 175
foot-pounds torque.
TRANSMISSION INSTALLATION
On the
121Y2
inch wheelbase Plymouth Station
Wagons, refer to Group
2,
"Torsion Bar Rubber Iso-
lator" for installation of the torsion bar rear an-
chor 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.
NOTE: Do not lubricate the end of the pinion
shaft,
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