REPAIR INSTRUCTIONS

19.Remove the temporarily installed No. 1 and No. 3 front countershaft rear bearing cover capscrews, covers and spacers.

20.Using a brass hammer, tap the No. 1 and No. 3 reverse idler shafts until fully seated in the case.

16.Place the transmission in a horizontal position.

17.Move the reverse gear and Lo/reverse sliding clutch to normal positions.

18.Position the mainshaft, No. 3 (lower) countershaft and No. 1 (upper right, when viewed from the front) countershaft so that the timing marks on the gears are aligned. Roll the shafts into place and make sure gear timing is correct.

Timing the shafts is easier if the transmission is in a horizontal position, rotated 15 degrees counterclockwise, as viewed from the rear of the transmission case.

21.Temporarily reinstall the No. 1 and No. 3 front countershaft rear bearing covers (without 1/2-inch thick spacers) to secure the countershafts. Jiggle the countershafts while tapping the covers in place. Install the capscrews, but do not tighten to specification at this time. Front countershaft bearing preload must be adjusted after main case assembly.

Do not use the bearing cover capscrews to pull any bearing cover into place. Damage to the bearings or bearing cover may result. Make sure all components are properly in place before tightening the capscrews.

22.Install the remaining No. 2 reverse idler shaft, gear and thrust washer (next to No. 2 countershaft, not yet installed) as described in the steps for the lower (No. 3) reverse idler shaft and gear. Move the reverse speed gear on the mainshaft as far away as possible. When installing the reverse idler shaft and gear, make sure that the thrust washer is held in place.

Setting Front Countershaft Bearing Preload

24.Install enough shims under the No. 3 (lower) and No. 1 (upper left, when viewed from the rear) front countershaft rear bearing cover to produce measurable countershaft end play. Then install the cover and tighten the capscrews to the specified torque. Measure end play of the countershaft, using a dial indicator.

Make sure that the thrust washer is aligned correctly with the idler shaft while tapping the idler shaft into place. If not aligned, damage to the thrust washer may result.

23.Shift the Lo/reverse sliding clutch and reverse gear rearward, to allow the gear teeth on the reverse speed gear to engage all three reverse idler gears. Temporarily install a folded rag between the Lo and reverse speed gears to hold them in place.

Use a pry bar to move the countershaft up and down while measuring end play on the dial indicator.