Transmission Reassembly
NOTE:
Apply SAE 75W-85 transmission fluid to components prior to installation.
- Install input shaft with input shaft needle bearing onto main shaft. Install mainshaft and input shaft assembly into lower case. Ensure smooth engagement with countershaft. Shift all gears to neutral. Apply silicone sealer to upper and lower case halves. Install upper case to lower case and torque bolts to 17 ft. lbs. (23 N.m).
- Install input shaft bearing retainer to upper and lower case. Secure with 8 bolts and torque to 17 ft. lbs. (23 N.m). For 2WD models, go to next step. For 4WD models, install rear case main seal. See Fig 1 . Go to step 4).
- On 2WD, install rear extension case oil seal. Apply grease and install select guide pins, select return springs and spring bolts. See Figure . Tighten bolts to 24 ft. lbs. (32 N.m). Ensure each pin moves smoothly. Install speedometer driven gear assembly into extension case.
- Clean rear case/extension case and transmission mating surfaces. Apply silicone sealant to mating surfaces and install on transmission. Torque bolts to 17 ft. lbs. (23 N.m).
- Clean gear shift lever case and rear case/extension case mating surfaces. Apply silicone sealant to shift lever case. Install and torque bolts to 12 ft. lbs. (17 N.m). Install clutch housing and bolts. Torque to 33 ft. lbs. (45 N.m). Install clutch release bearing.