2. Clamp the rear crankcase in a vice, heat the housing around the bearing seat to approximately 100°C.
3. Lower the gearbox into the housing, making sure that the secondary shaft bearing is fully seated (photo).
4. Place the snap ring in the groove, remove the piece of wire.
5. Place the output flange on the secondary shaft slots, screw on the nut. Fix the flange and tighten the nut with the tightening torque specified Specification (photo).
6. Place the needle bearings in the reverse idler gear, place the gear on the housing, insert the shaft. Note that the identification groove on the mechanism should be facing forward (photo).
7. Insert and tighten the reverse intermediate shaft bolt.
8. Lubricate the two locking pins and insert them between the holes in the leash roller (photo).
9. Insert the 5/3X gear engagement fork into the groove in the 5/3X gear synchronizer sleeve (photo).
10. Check that all synchronizer bushings are in neutral position.
11. Insert the 1/2 gear selector fork into the groove in the 1/2 gear synchronizer sleeve. Insert the 1/2 gear carrier shaft through the fork into the rear case, then place the selector clamp on the shaft (photo).
12. Insert the 3/4 gear shift fork into the groove in the 3/4 gear synchronizer sleeve. Insert the 3/4 gear shifter shaft through the fork into the rear case and turn until the shifter fingers align (photo).
13. Lubricate the four rollers and place them on the pins on the gear shift lever shaft (photo).
14. Insert the gearshift lever shaft with the selector pin into the rocker arm. Use a screwdriver to turn the rocker arm as needed to help the shaft enter and to allow the selector pin to enter the switches (photo).
15. Insert the 5/3X gear shift shaft through the 5/3X gear engagement fork into the rear housing (photo).
16. On each leash roller, align the holes, hammer in the cylindrical pins until they protrude outward by approximately 1.0 mm (photo).
17. Insert the ball retainers and springs into the rear housing.
18. Apply sealant to the retainer plate (photo), then install it on the springs, insert the bolts and tighten them to the tightening torque specified in the Specification.
19. Engage 4th gear and check that the remaining synchronizer rings are not clamped on their respective gear cones. If necessary, loosen the rings with a screwdriver.
20. Apply sealant to the rear case mating surface (photo).
21. Carefully lower the main housing onto the rear crankcase, making sure that the driver rollers and positioning mechanism enter their corresponding holes (photo).
22. To install the input shaft bearing, prepare a special tool. It is not permissible to simply hammer the bearing into place, this can damage the synchronizer rings. It is also impossible to install the bearing retaining ring. GM tool #KM-461 (photo). It is made from a cut metal tube to provide a clamp to grip the input shaft. Two side bolts are used to press the bearing into the housing, using metal blocks to prevent damage to the bearing.
23. Before installing the bearing, heat the housing around the bearing seat to approximately 100°C.
24. Place the bearing (with retaining ring) above the input shaft, using a special tool, insert it into the housing (photo). Check that the internal groove of the retaining ring is visible on the input shaft.
25. Remove the tool, then install the inner snap ring onto the input shaft.
26. Shift into neutral. Rotate the input shaft to ensure that the synchronizer rings are not pinched on their cones.
27. Insert the housing bolts, tighten them evenly with the specified tightening torque Specification (photo).
28. Insert the front bolt securing the reverse intermediate gear shaft and tighten it to the specified tightening torque Specification.
29. Remove the rubber O-ring from the clutch bearing guide sleeve. Clean the bearing surface, drive in a new seal using a metal tube or socket of the appropriate size. The closed side of the seal should be inside the sleeve. Install a new rubber O-ring (photo).
30. Lubricate the seal lip, then install the clutch release bearing guide sleeve, being careful not to damage it on the input shaft grooves. Insert the bolts, tighten them to the specified tightening torque Specification (photo).
31. Insert the gearshift shaft retainer pin and spring, making sure the pin roller is horizontal. Tap the cover into the housing with a mallet.
32. Install the speedometer drive gear and housing. Insert and tighten the bolt.
33. Insert and press the reverse light switch (photo).
34. Install the release bearing and lever as described in Section 5.
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