f.
Replace all gaskets, o-rings, oil seals, and sealing washers each time transmission is disassembled. Replace
bushings and bearings worn beyond tolerance.
g.
Replace any part found badly worn or otherwise damaged.
4-10.3.4 Assembly.
a.
If bearings were removed from shafts, inside gears, or inside the housing, reinstall bearings using a small arbor
press. Be sure to apply pressure to the member being installed (inner ring on a shaft; outer ring in housing or
gear). Start bearing squarely on shaft or in housing or gear and be sure it seats squarely against shoulder. Oil
bearings and bushings during assembly to assure lubrication during the first few moments of operation. Install
new oil seals by pressing against the outside diameter.
b.
With the housing on its side, begin assembly by setting the low gear (46) in the transmission against the rear wall
with its splined hub toward the front. Next place the second gear (47), with the shift collar side toward the front,
in front of the low gear. Now place the third gear (48), with its shift collar side toward the rear, in front of the
second gear. From the front of the transmission, insert the output shaft (49) into the housing and through the
gears. Work the shaft in until all gears are splined on the shaft.
c.
Carefully set the housing upside down and continue assembly with the countershaft. If not already assembled,
press-fit bearings (52) into second and third countershaft gears (53, 57). (Bearings must be flush to 0.003" below
the machined edge of the gear.) Install the bearing sleeve (56) into third gear (57). With bearing (50) installed on
the countershaft (51), and bearing (59) installed in the housing, insert the countershaft through the rear of the
housing as you install second gear (53), with its splined hub facing the front. Next, install the shifting collar hub
(55), then the shifting collar (54) onto the hub. Install third gear (57) with its splined hub facing the rear. Finally,
install the drive gear (58). Be sure the countershaft is fully seated in the housing.
d.
Carefully set the housing upright. Install the thirty-four loose roller bearings (45) under the output shaft low gear
(46), rotating the shaft as required to get all the bearings to seat into place. Then install the thrust washer (44)
and the output shaft bearing (43).
e.
Position the shift cap (17) in a fixture to assemble the shift cap. If any were removed, install shift stop pins (15).
Install two springs (14) and steel balls (12) in the shift cap. Assemble the shift selectors (13) and shafts (16),
attaching shafts to selectors with retaining pins (4). Install the assembled shift arms into the shift cap. Position
the steel ball (12) between the shift selectors. Carefully place the inhibitor block (11) in position and install two
drilled-head screws (3). Tighten the capscrews and install the safety wire (7) in the capscrew's heads.
f.
Turn the shift cap over and install two new oil seals (6). Install the two shifting arms (5), fastening each with a
retaining pin (4). Install the shifting forks (9, 10). Install a new shift cap gasket (19); then aline the shifting forks
with the shifting collars in the transmission and install the assembled shift cap (1) onto the housing (64). Install
six capscrews (2) and sealing washers (3).
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