Assembly

1. Using press and Valve Stem Seal Replacer T91P-6571-A, install input shaft pocket support bearing onto output shaft.

CAUTION: Do not support output shaft by flange as damage will result.





2. Using petroleum jelly, lube and install second speed gear needle bearing.





3. Install second speed gear over needle bearing.





4. Install thrust washer over splines.





5. Install first and second gear synchronizer inner cone over thrust washer as shown.

NOTE: Make sure inner splines of first and second gear synchronizer inner cone are indexed with thrust washer.





6. Install second gear middle blocker ring over first and second gear synchronizer inner cone.

NOTE: Soak blocker ring in MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

NOTE: Make sure tabs on blocker ring align with pockets on second gear.





7. Install second gear outer blocker ring over middle blocker ring.





8. Place first-second synchronizer onto output drive shaft.

NOTE: Groove on synchronizer sleeve must face toward the rear of output shaft.





9. Using Bearing Replacer Tube T77L-7025-C, Remover/Replacer Tube T75L-7025-C and Replacer/Adapter T96P-7025-A, press first-second synchronizer onto splines by tightening nut on Replacer/Adapter T96P-7025-A.

NOTE: Make sure inserts on synchronizer align with pockets on outer blocker rings.





10. Index and install first speed outer blocker ring.

NOTE:
^ Align triangular marker on outer blocker ring with arrow on synchronizer.
^ Soak blocker ring in MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.





11. Install first speed middle blocker ring as shown.

NOTE:
^ Tabs on middle blocker ring must face up.
^ Soak blocker ring in MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.





12. Install first and second gear synchronizer inner cone as shown.





13. Install first and second speed synchronizer thrust washer as shown.








14. Install first speed retaining ring onto output shaft.





15. Using petroleum jelly, lube and install first speed needle bearing.





16. Install first gear over needle bearing.

NOTE: Tabs on middle blocker must align with pockets on first gear.





17. Place new tapered roller bearing onto output shaft. Using Remover/Replacer Tube T75L-7025-C and Replacer/Adapter T96P-7025-A, press into place.





18. Press fifth speed gear onto output shaft with chamfer facing toward tapered bearing using Remover/Replacer Tube T75L-7025-C and Replacer/Adapter T96P-7025-A, and threaded rod





19. Install bearing and third speed gear bearing spacer assembly onto output shaft.





20. Install third speed gear over needle bearing.





21. Install third speed synchronizer blocking ring over third gear.

NOTE: Soak blocker ring in MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.





22. Using Bearing Replacer Tube T77L-7025-C and press, support output shaft from rear, press third/fourth synchronizer onto output shaft as shown with groove forward.

CAUTION: Third/fourth synchronizer struts must index with pockets in third speed blocker ring assembly during press operation to prevent damage.








23. Install third/fourth synchronizer retaining ring onto output shaft.