until the necessary shim thickness is determined.
17-4. Reassembly and Installation of Subassemblies
(9) Install the speedometer drive gear in the case.
b. Range Selector Housing (Range Box).
a. Rear Output Shaft and Differential Housing Assembly.
(1) Installing the countershaft gear assembly.
(1) Position the flat rubber seal ring in the bearing
bore. Use grease to hold it in place. Position the roller bear-
(a) Using heavy grease for retention, install the
ing in the differential housing bore and press it in until the
roller bearings (72 required) and spacers in the counter gear
bearing bottoms in the housing.
(2) Position the rear bearing in the output shaft
(b) Using heavy grease, position the countershaft
housing and tap or press it into place.
thrust washers in the case. Engage the tab on the washers
with a slot in the case thrust surface.
(3) Install the rear output shaft seal into the output
(c) Position the countergear assembly in the case
and install the countershaft into the gear assembly through
(4) Install two new seals on the inside surface of the
the front face of the range box. The flat countershaft face
output housing, centering the holes at the vent opening (fig-
should face forward and must be alined with the case gasket.
(A 1.490-inch diameter dummy shaft will aid in reinstalling
(5) Position the sealing "0" ring on the differential
(2) Installing input gear assembly.
(a) Install a bearing (without the large snap ring)
on the input gear shaft, positioning the snap ring groove out-
ward. Install a new retaining ring on the shaft. Position the
input gear and bearing in the housing. The retaining ring is
a select fit. Use service ring size A, B, C, or D to provide the
(b) Install a snap ring into the groove in the outer
diameter of the bearing.
(c) Aline the oil slot in the retainer with the drain
hole in the case. Install the input gear bearing retainer, gas-
ket, and retaining bolts. Tighten to 20 ft-lbs.
(3) Installing the shifter shaft assembly.
(a) If removed, install the detent plate and the
pivot pin assembly in the housing. Use a sealant on the pin.
(b) Install new "O" rings on the inner and outer
shafts. Lubricate the rings and assemble the inner shaft in
the outer shaft.
(c) Push the shifter shafts into the housing en-
gaging the long end of the lockout clutch connector link
to the outer shifter shaft before the shaft assembly
(d) Install the lockout shift lever and retaining
Figure 17-13. Rear Output Housing Assembly.
(6) Install the retainer housing assembly on the dif-
(e) Install the range selector shift lever and the
ferential housing. Tighten the six capscrews to 30 ft-lbs.
shift shaft retaining nut.
(7) Install the speedometer drive gear and shims
(f) Install the shift fork and the sliding clutch
(approximately 0.050 inch thickness) on the output shaft.
gear. Push the fork up into the shifter shaft assembly to
Install the shaft into the carrier through the front opening.
engage the detent plate sliding the clutch gear forward
(Be careful not to damage the pump oil seal.)
onto the input shaft gear.
(8) Install the yoke, rubber seal, washer, and re-
(g) Install the detent plate spring, gasket, and
taining nut. Leave the nut approximately 1/16-inch loose
plate in the top of the housing. Check the spring engage-
ment with the detent plate.
(4) Reassembling the input shaft assembly.
(a) Position a bearing on the retainer bore and
press or tap it into place.
(b) Install a large snap ring retaining bearing in .