Assembly

Transmission





















NOTICE: Lubricate all components with the recommended transmission fluid before assembling.

1. NOTICE: Do not heat the input shaft bearing higher than 120°C (248°F) maximum or damage to the input shaft bearing can occur.

Using a suitable heat gun, heat the input shaft bearing inner race to a maximum of 120°C (248°F).





2. With the oil feed hole facing the countershaft bearing, install the input shaft.





3. Install the input shaft snap ring.





4. NOTICE: Make sure the small diameter side of the output shaft roller bearing cage is facing the input shaft or damage to the output shaft bearing can occur.

With the small diameter side of the output shaft roller bearing cage facing the input shaft, install the output shaft roller bearing.





5. NOTE: Apply petroleum jelly to hold the 5th gear synchronizer ring and the 5th gear synchronizer cone in place during assembly.

Install the 5th gear synchronizer ring and the 5th gear synchronizer cone.





6. Assemble the shafts with the oil feed hole on the 5th gear cone facing the countershaft.





7. NOTICE: Do not heat the countershaft bearing higher than 120°C (248°F) maximum or damage to the countershaft bearing can occur.

Using a suitable heat gun, heat the countershaft bearing inner race to a maximum of 120°C (248°F).





8. With the oil feed holes aligned, install the output shaft and countershaft assembly.





9. NOTICE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

Install the 5th/6th shift fork, the 5th/6th shift rail and loosely install the shift fork pivot bolts.

- Apply Threadlock and Sealer to the shift fork pivot bolts.





10. NOTICE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

Install the 3rd/4th shift fork, the 3rd/4th shift rail and loosely install the shift fork pivot bolts.

- Apply Threadlock and Sealer to the shift fork pivot bolts.





11. Tighten the 2 LH and the 2 RH shift fork pivot bolts.
- Tighten to 37 Nm (27 lb-ft).





12. Push down the 3rd/4th shift rail and the 5th/6th shift rail to lock the transmission into 2 gears.





13. NOTICE: Apply Threadlock 262 to the countershaft bolt or damage to the transmission can occur.

Install the countershaft bolt.

- Apply Threadlock 262 to the countershaft bolt.

- Tighten to 95 Nm (70 lb-ft).





14. Pull up on the 3rd/4th shift rail and the 5th/6th shift rail to unlock the transmission from 2 gears.





15. NOTICE: When installing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

Slightly expand the center support bearing cages and slide the center support bearings down the shaft assemblies. Lock the bearing cage tabs.





16. NOTICE: The center support must be tightened evenly or damage to the center support or transmission case can occur.

Install the center support and evenly tighten the 3 center support bolts.

- Apply Threadlock 262 to the 3 center support bolts.

- Tighten to 24 Nm (18 lb-ft).





17. Install the spring and spacers.





18. NOTE: Make sure the interlock plate moves freely.

Install the interlock plate and the 2 interlock plate bolts.

- Apply Threadlock 262 to the 2 interlock plate bolts.

- Tighten to 24 Nm (18 lb-ft).





19. Install the 2nd gear needle bearing.





20. Install the 2nd gear.





21. NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the synchronizer ring assembly can occur.

NOTE: The 2nd gear synchronizer ring assembly outer ring has 2 identification notches.

Install the 2nd gear synchronizer ring assembly.





22. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer hub slots or damage to the synchronizer hub and the synchronizer ring assembly can occur.

NOTICE: The long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear or damage to the synchronizer hub can occur.

With the long shoulder of the 1st/2nd synchronizer hub facing 2nd gear, use the Synchro Gear Pack Installer and install the 1st/2nd synchronizer hub.





23. Install the 1st/2nd synchronizer hub snap ring.





24. NOTE: Align the index marks made during removal on the synchronizer sleeve and the synchronizer hub.

With the groove on the 1st/2nd synchronizer sleeve facing 2nd gear, install the 1st/2nd shift fork the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.





25. NOTE: Slide the synchronizer sleeve up to install the pressure pieces.

Install the 3 pressure pieces.





26. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and the synchronizer ring assembly can occur.

NOTE: The 1st gear synchronizer ring assembly outer ring has one identification notch.

Install the 1st gear synchronizer ring assembly.





27. Install the 1st gear needle bearing.





28. NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

Install the 1st gear.





29. Using the Synchro Gear Pack Installer, install the reverse gear needle bearing race.





30. Install the reverse gear needle bearing.





31. Install the reverse gear.





32. NOTICE: The shift shaft must be installed in the neutral position prior to installing the shift shaft stop pin or damage to the shift shaft stop pin can occur.

Install the shift shaft in the neutral position, using a soft-faced hammer install the shift shaft stop pin.





33. Install the reverse gear synchronizer ring.





34. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and the synchronizer ring can occur.

Using the Synchro Gear Pack Installer, install the reverse gear synchronizer assembly.





35. NOTE: To install the reverse shift fork and the reverse shift rail assembly, the transmission must be in neutral and the groves on the shift rails must be aligned with the interlock plate.

Install the reverse shift fork and the reverse shift rail assembly.





36. Install the magnet.





37. Shift the transmission into 4th gear.





38. NOTE: Do not wait longer than 10 minutes to install the rear transmission case assembly due to the rapid cure time of the sealant.

Clean the sealing surfaces of the front transmission case and the sealing surfaces of the rear transmission case. Thinly coat the sealing surface of the front transmission case assembly and the sealing surface of the rear transmission case assembly with Gasket Maker.

39. NOTICE: The rear transmission case assembly must be installed evenly with the transmission shifted into 4th gear, do not allow the shift rails to bind during installation or damage to the transmission case assembly can occur.

Using the Synchro Gear Pack Installer and the Rear Flange Installer, install the rear transmission case assembly.





40. NOTICE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

Install the 2 shift fork pivot bolts.

- Apply Threadlock and Sealer to the shift fork pivot bolts.

- Tighten to 37 Nm (27 lb-ft).





41. Loosely install the 15 transmission case bolts.





42. Using a suitable brass drift, tap the 2 dowel pins flush with the transmission case.





43. Tighten the 15 transmission case bolts.
- Tighten to 24 Nm (18 lb-ft).





44. Using a soft-faced hammer install the 4 shift rail detents.





45. If equipped, install the skip shift solenoid pin and spring.





46. If equipped, seat the skip shift solenoid into the transmission case and hold, while securing the 2 skip shift solenoid bolts.
- Tighten to 10 Nm (89 lb-in).





47. Install the reverse lamp switch.

1. Install the reverse lamp switch.
- Tighten to 20 Nm (177 lb-in).

2. Attach the electrical connector retainer.





48. Install the Output Shaft Speed (OSS) sensor and the OSS sensor bolt.
- Tighten to 10 Nm (89 lb-in).





49. Install a new output shaft seal on the Rear Seal Installer and Handle.





50. Using the Rear Seal Installer and the Handle, install the output shaft seal.





51. Using the Synchro Gear Pack Installer and the Rear Flange Installer, install the output shaft flange.





52. Install the Drive Pinion Flange Holding Tool and the Rear Flange Holding Tool on the output shaft flange. Clean the threads on the output shaft bolt and apply one dot of Threadlock 262 to the lower end of the output shaft bolt threads. Using the Drive Pinion Flange Holding Tool and the Rear Flange Holding Tool, install the output shaft flange bolt. Tighten the output shaft flange bolt in 3 stages.
- Stage 1: Tighten to 200 Nm (148 lb-ft).

- Stage 2: Loosen the output shaft flange bolt.

- Stage 3: Tighten to 180 Nm (133 lb-ft).





53. Using the Rear Seal Installer and the Handle, install the countershaft bolt cover.





54. Using the Front Seal Installer, install the new input shaft seal.





55. Install the clutch slave cylinder and if equipped, the clutch slave cylinder spacer.

1. Position the clutch slave cylinder and if equipped, the clutch slave cylinder spacer and connect the tube in the retaining clip.

2. Install the 2 clutch slave cylinder bolts.
- Tighten to 11 Nm (97 lb-in).