group 6 Manual Shift Transmissions.pdf - Index of

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6-28 GROUP 6-Manual Shift Transmissions
15. Remove the input shaft and
."-,
bearing and the blocking ring from
~SET SCREW. 3778~ - S
the front of the case.
16. Move the output shaft to the
;;-SPRING.7234
right side of the case to provide clearance
for the shift forks. Rotate the fork
~
as shown in Fig. 7, then lift them from
~DETENT PLUG. 7C316
the case.
FIRST AND SECOND SPEED SHIFT RAil
17. Support the thrust washer and
7240
first-speed gear to prevent them from
.THIRD AND FOURTH ffi- SCREW - 377886 - S
sliding off the shaft, then lift the output
SPEED SHIFT FORK. 7230 IJ
shaft assembly from the case as
FIRST AND SECOND
shown in Fig. 8.
i. 377886. S
SPEED SHIFT FORK. 7230
18. Remove the reverse gear shift
DETENT PLUG-@
fork set screw. Rotate the reverse
7C316
INTERLOCK PIN ,q
shift rail 900 as shown in Fig. 9.
7235 Y
Slide the shift rail out the rear of the
case. Lift the reverse shift fork from
the case.
19. Remove the reverse detent
-THIRD AND --. FOURTH WDETENT PLUG- 7C316 -
plug and spring from the case with
SPEED SHIFT RAIL
a magnet.
7Al
20. Remove the reverse idler gear
shaft from the case as shown in Fig.
11\ DETENT PlUG-(J
REVERSE SHIFT RAil
REVERSE
--.
21. Lift the reverse idler gear and
the thrust washers from the case. Be
careful not to drop the bearings and
the dummy shaft from the gear.
22. Lift the countershaft gear and
the thrust washers from the case. Be
careful not to drop the bearings or the
dummy shaft from the countershaft
gear.
23. Remove the snap ring from
the front of the output shaft. Slide the
third- and fourth-speed synchronizer
(Fig. 11) blocking ring and the thirdspeed
gear off the shaft.
24. Remove the next snap ring
and the second-speed gear thrust washer
from the shaft. Slide the second-speed
gear and the blocking ring off the
shaft.
25. Remove the next snap ring,
first speed gear and blocking ring.
26. Remove the thrust washer
from the rear of the shaft. The first and
reverse synchronizer hub is a press fit
on the output shaft. To eliminate the
possibility of damaging the synchronizer
assembly, remove the synchronizer
hub using an arbor press. Do not attempt
to remove the hub by hammering
or prying.
PARTS REPAIR OR
REPLACEMENT
GEAR SHIFT
CONTROL ASSEMBLY
. I. After removing the six screws
from the gear shift lever boot retainer.
slide the retainer and boot up on the
lever. Remove the plungers and springs
from the lever (Fig. 12).
2. Remove the two bolts retaining
the shift lever to the trunion and remove
the shift lever.
EXPANSION
PLUG - 74112-5
FIG. 5-Shift
7C316. 7240
SPRING --:
7234 .
Rails and Forks Disassembled
3. Raise the vehicle on a hoist.
4. Disconnect the three shift rods
at the transmission by removing the
hair pin type retainer (Fig. 3).
5. Remove the three bolts retaining
the shift assembly to the transmission
extension housing and remove the shift
assembly.
6. Remove the back up light switch
from the shift assembly.
7. Remove the snap ring from the
end of the selector shaft with pointed
snap ring pliers (Fig. 12).
8. Remove the flat washer and
spring.
9. After removing two bolts, pull
the retainer, selector levers and bracket
from the shaft.
10. Drive the short selector lever
pin from the shaft with a large pin
punch.
11. Drive the long trunion pin from
1"'"
l.iW~~;;:!;;ifJ
SCREW ~
377886 - S ~
SHIFT FORK
7231
DETENT PLUG -7C316
SPRING
7234
I
ffj-MAGNETIC DRAIN PLUG -373719-5
BOLT
378206.:
C 1568- A
the shaft and remove the trunion and
shaft.
12. Clean and inspect all parts.
13. Lubricate all mating friction
surfaces with Rotunda Lube CIAZ-
19586-B.
14. Install the shaft in the bracket.
Position the trunion and drive the
long straight pin through the trunion
and into the shaft until an equal length
of the pin is exposed on both sides
of the shaft.
15. Drive the short pin into the shaft
until the pin is centered in the shaft.
16. Install the selector levers and
neutral index on the shaft as shown in
Fig. 12.
17. Position the retainer and start
the bolts. Before tightening the bolts,
be sure that the retainer is not interfering
with free movement of the shaft.
Tighten the bolts.