l. Install taper bearing (113) on output shaft (86).
ing cap bolts (69) and washers (70). Tighten bolts to
Position gears (94) and (95) in transmission case so
47-55 ft-lb (63.7--74.6 N. m). Install oil deflector
that the gears are properly stacked. Insert shaft (86)
(68), companion flange (67), packing (66) flange washer
through the bearing bore and gears (94) and (95). Block
(65) and flange nut (64). Tighten nut to 150-175 ft-lb
the shaft and install bearing (107) with large diameter
(203.4--237.3 N. m). Secure with cotter pin (63).
inward, until bearing shoulders against the gear. In-
r. Press bearing (112) onto reverse shaft (81) as indi
stall bearing cups (114) and (108) over the bearing
cated. Install short spacer (83) on the shaft. Position
reverse gear (82) in the case with longer offset of the
m. Refer to figure 15-3 and assemble the disconnect
gear to the rear. Install reverse shaft, spacer and bear-
ing assembly into the case bore and through the reverse
(1) Install bearing (19) in bore of housing (20). In-
gear. Using a suitable shaft pusher tool, push the
stall shift fork (10) and bushing (8) on shaft (17). Insert
reverse shaft into the bore until the bearing seats
the assembled shaft into housing (20) and through
against the bearing bore. Do not remove the pusher tool
bearing (19). Secure the shaft with snap ring (16).
at this time. Install large spacer (84) on shaft (81)
(2) Install detent ball (14) and detent spring (13)
against the reverse gear. Drive bearing (110) into place
into position in the housing, and insert shift rail (15)
until spacer (84) cannot be turned by hand. Do not at-
into position. Secure the shift rail in position with set
tempt to draw the bearing into position with the bear-
screw (9). Install oil seal (12).
ing lock nuts. Remove shaft pusher tool.
(3) Install oil seal (7) and deflector (6) on the
s. Install gear spacer (80) and nut (79) on shaft (81).
shaft. Install flange (5), packing (4), flange washer (3)
Tighten nut (79) to 150--175 ft-lb (203.4--237.4
N m). Install cotter pin (78). Install new gasket (77)
and flange nut (2). Secure with cotter pin (1). Install
packing (18) on the housing.
and bearing cap (76). Install bearing cap bolts (74) and
n. Refer to figure 15-1. Install disconnect assembly
lock washers (75).
(55) on the transmission case and secure with screws
t. Lock gears using a soft bar. Install bearing inner
(52) and (53) and lock washers (54). Tighten screws to
lock nuts (48) and (50) on all four shafts. Tighten lock
nuts to 175-200 ft-lb (237.4--271.2 N m). Install
47-55 ft-lb (63.7-74.6 N. m). Temporarily install
flange nut (26) on the output shaft. Using an inch-lb.
center lock nuts (49) and (51), and outer lock nuts (48)
torque wrench, turn the output shaft and gear train.
and (50). Tighten outer lock nuts to 175--200 ft-lb
(237.4-271.2 N m). Bend tangs on center lock nuts
Record the information and remove the flange nut.
o. Install oil seal (88) and packing (87). Install shims
alternately over flats on the inner and outer lock nuts.
(37) and bearing cap (36). Secure with screws (34) and
u. Install clutch supports (42) and (43) and secure
lock washers (35). Tighten screws (34) to 47--55 ft-lb
with screws (40) and (41). Tighten screws to 70-85 ft-
lb (94.9-115.2 N m). Install new piston rings (32)
(63.7-74.6 N m). Install flange (29), packing (28),
flange washer (27) and flange nut (26). Using the inch-
and (33). Lubricate piston rings with automatic
pound torque wrench, turn the output shaft and gear
transmission fluid. Install large idler gear (39) with
train. When bearings are properly preloaded, it will re-
longer offset of gear hub inward. Install idler gear re-
quire 6 to 8 inch-pounds more to turn the gear train
tainer ring (38).
and shaft than it did in the previous step. Add or
v. Refer to figure 15-3 and tighten flange nut (2) to
remove shims until proper preload is attained. Install
250-300 ft-lb (338.9-406.7 N m).
cotter pin (25).
w. Refer to figure 15-1. Install small idler gear (60)
p. Press bearing (112) onto shaft (85) as indicated.
and secure with snap ring (59).
Install short spacer (83) on the shaft. Position input
x. Refer to figure 15-4 for assembly procedures for
gear (82) in the case with longer offset of the gear to
the first and second clutch assemblies.
the rear. Install input shaft, spacer and bearing assem-
(1) Insert lock ball (21) into outer race (20). Press
bly into the case bore and through the input gear.
outer race and ball assembly into clutch drum (22).
Using a suitable shaft pusher, push the shaft into the
Outer race must be pressed from flush to one-sixty-
bore until the bearing seats against the case bore. Do
fourth of an inch below shoulder in the clutch drum.
not remove the pusher tool at this time. Install larger
(2) Press support ball bearing (19) into clutch
spacer (84) on shaft (85) against the gear. Drive bear-
drum and secure with snap ring (7). From the rear end
ing (110) into place until spacer (84) cannot be turned
of the clutch drum, press support roller bearing (18) in
by hand. Do not attempt to draw the bearing into posi-
drum (22). Secure with snap ring (16).
tion using the bearing lock nuts. Remove shaft pusher
(3) Press clutch drum hub gear (14) on clutch
drum with longer offset of gear hub inward. Secure
q. Apply a thin coat of sealant on the outer diameter
with snap ring (13).
of seal (73). Press seal (73), (lip of seal inward) into in-
(4) Install clutch drum assembly on clutch support
put shaft bearing cup (71). Install new gasket (72) and
bearing cap (71) on the transmission case. Install bear-