Advertisement
PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION
6-33
2.
Position the countershaft gear,
dummy shaft, and roller bearings in
the case.
3.
Place the case in a vertical posi-
tion. Align the gear bore and the
thrust washers with the bores in the
case and install the countershaft.
4.
Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0 · 004-0 · 018
within specification. If not within
these limits, replace the thrust
washers.
5. After establishing the correct
end play, install the dummy shaft in
the countershaft gear and allow the
gear to remain at the bottom of the
case.
6.
Coat the reverse idler gear thrust
surfaces in the case with a thin film
of lubricant and position the two
thrust washers (Fig. 66) in place ..
7. Position the reverse idler gear,
sliding gear, dummy shaft and the
roller bearings in place making sure
that the shift fork groove in the slid-
ing gear is towards the front of the
case.
8. Align the gear bore and thrust
washers with the case bores and in-
stall the reverse idler shaft.
9.
~easure
the reverse idler gear
end play with a feeler gauge. End
play should be within specification. If
the end play is not within limits, re-
place the thrust washers. If the end
play is within limits, leave the reverse
idler gear installed.
10. Position the reverse gear shift
rail detent spring and detent plug in
the case. Hold the reverse shift fork
in place on the revers<.: idler sliding
gear and install the shift rail from the
rear of the case. Secure the fork to
the rail with the Allen head setscrew.
FIG. 63
-Installing Input
Shaft Seal
INSERT! SPRING
FIRST AND SECOND SPEED SYNCHRONIZER
ETCH MARKS
INSERT SPRING
INSERT SPRING
~
"""'(
"v
GROOVE TO FACE
TOWARD FRONT
OF TRANSMISSION
THIR'D AND FOURTH SPEED SYNCHRONIZER
FIG. 64
-Synchronizers Disassembled
11.
Install the first- and second-
speed synchronizer onto the front of
the output shaft (Fig. 69) making
sure that the shift fork groove is to-
ward the rear of the shaft. The first
and reverse synchronizer hub is a
press fit on the output shaft. To
eliminate the possibility of damaging
the synchronizer assembly, install the
synchronizer hub with the teeth end
of the gear facing toward the rear of
the shaft, using an arbor press as
shown in Fig. 69. Do not attempt
to remove or install the hub by
hammering or prying.
12.
Position the blocking ring on
the second-speed gear.
13. Slide the second-speed ·gear
onto the front of the shaft, making
sure that the inserts in the synchro-
nizer engage the notches in the
blocker ring.
14. Install the second-speed gear
thrust washer and snap ring.
15. Slide the third-speed gear onto
the shaft with the synchronizer
coned surface toward the front.
16.
Place a blocking ring on the
third-speed gear.
17. Slide the third- and fourth-
speed gear synchronizer onto the
shaft making sure that the inserts in
the synchronizer engage the notches
in the blocking ring.
18. Install the snap ring on the
front of the output shaft.
19. Position the blocking ring on
the first-speed gear.
.
20.
Slide the first-gear speed onto
the rear of the output shaft making
sure that the notches in the blocking
ring engage the synchronizer inserts.
21.
Install the heavy thrust washer
on the rear of the output shaft.
22. Support the thrust washer and
first-speed gear to prevent them from
~liding
off the shaft and carefully
lower the output shaft assembly into
the case as shown in Fig. 56.
23.
Position the first- and second-
speed shift fork and the third- and
fourth-~peed
shift fork in place on
their respective gears and rotate them
into place.
24. Place a detent plug (Fig. 53)
in the detent bore. Place the reverse
shift rail into neutral position.
25. Coat the third- and fourth-
speed shift rail interlock pin with
grease and position it in the shift rail.
26. Align the third- and fourth-
speed shift fork with the shift rail
Advertisement
