Filed Under (Tips and Review) by admin on 03-03-2011

DISASSEMBLY For 5 speed gear set removal refer to your factory service manual. You willneed to remove the main drive gear, main drive gear bearings, retaining clip & countershaft needle bearings. NOTE: Removal of the shifter arm is notnecessary for 99 & earlier transmissions. NOTE: Removal of the shifter arm isnecessary for 2000 & later transmissions. After trans. housing is disassembled thoroughly clean & inspect. ASSEMBLY For 2000 & later models removal of approximately 1/4 of an inch off of the shifter arm bushing is likely required. Doing so will allow installation of the retaining clip & washer onto the shifter arm. It is good practice to double check how much material should be removed before cutting the bushing. See fig. 1 & 2 Install supplied Main drive gear bearings & countershaft needle bearings using special tool # 97-164 NOTE: Lightly coat bearings with assembly lube or gear oil for easier installation. Install supplied Main drive gear retaining clip & verify that it is fully seated and cannot come out. Do not re-use old bearings or retaining clip. Install supplied Main drive gear into bearings using special tool # 97-166 See fig. 3 Install supplied trap door gasket & verify that it is on correctly. Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly. Slowly slide in gear set until the mainshaft & countershaft will not slide in any further. Lightly tapping on the trap door (while verifying that there is no interference) with a soft blow hammer will then fully seat the shafts & trap door. See fig. 4 Once gear set is installed use the supplied 5/16-18×1-1/2 & 1/4-20×1-1/2 bolts to secure the trap door. Torque the 5/16 bolts to 15 ft-lbs w/ red loctite (high strength) Torque the 1/4 bolts to 9 ft-lbs w/ red loctite (high strength) See fig. 5