For 1990-2009 cars

#### Tools Required

• | DT-47735 Pinion Flange Holder

• | J 35467 One-Way Clutch Tester

• | J 44731 Input Shaft Seal Installer

1. Apply an approved lubricant to each gear shift fork and gear shift head (1).
2. Join the shift rail assembly to the input shaft (3) and countershaft assembly (2).
3. Install the input shaft, countershaft and shift rails as an assembly (1) in the clutch housing (2).
4. Install the snap ring (1) into the groove of the input shaft radial ball bearing.
5. Install the snap ring (1) into the groove of the countershaft radial ball bearing.
6. Apply an approved threadlocker to the shift rail retaining bolts (1).

Notice: Refer to Fastener Notice in the Preface section.

7. Install the shift rail (2) to clutch housing retaining bolts (1)

Tighten
Tighten the bolts to 21 N·m (15 lb ft).

Important: During alignment, ensure that the thread hole of the reverse idler gear shaft (1) aligns with the thread hole of the middle case.

8. Apply an approved lubricant and install the following components:

• | the reverse idler gear bearing (3)

• | the reverse idler gear (2) with the higher boss facing the rear

• | the reverse idler gear shaft (1) with its hole facing outward

9. Apply an approved lubricant and install the input shaft bearing (2), blocking ring (3) and the rear output shaft (1).
10. Install the shift shaft selector lever (1) to the clutch housing (2).

Notice: Refer to Machined Surface Damage Notice in the Preface section.

11. Apply an approved sealer the interface of the clutch housing (2) and the intermediate case (1).
12. Apply an approved lubricant to the shift and select lever shaft bearing.
13. Install the intermediate case (1) to the clutch housing.
14. Install the inner clutch housing to intermediate case retaining bolts (1).

Tighten
Tighten the bolts to 40 N·m (29 lb ft)

15. Install the outer clutch housing to intermediate case retaining bolts (2).

Tighten
Tighten the bolts to 40 N·m (29 lb ft)

16. Install the oil trough pipe (1) to the intermediate case.
17. Install a NEW gasket (3) to the reverse idler gear shaft retaining bolt (2).
18. Install the reverse idler gear shaft retaining bolt (2) to the intermediate case.

Tighten
Tighten the bolt to 40 N·m (30 lb ft)

19. Install the oil trough (2) to the intermediate case.
20. Install the oil trough (2) to intermediate case retaining bolts (1).

Tighten
Tighten the bolts to 8.5 N·m (75 lb in)

21. Apply an approved lubricant to the following components:

• | the tapered roller bearing outer race (2)

• | the cylindrical roller bearing (3)

• | the control sub-assembly holes (1)

22. Apply an approved lubricant to the following components:

• | the tapered roller bearing of the output shaft (1)

• | the cylindrical roller bearing inner race of counter gear (2)

23. Apply an approved sealer to the interface of either case.

Notice: Refer to Machined Surface Damage Notice in the Preface section.

24. Install the rear case to the intermediate case.
25. Install the rear case to intermediate case retaining bolts (1).

Tighten
Tighten the bolts to 40 N·m (29 lb ft)

26. Apply an approved lubricant and install the lock ball pin (1).
27. Install the spring (2) and a NEW plug (3) to the rear case.

Tighten
Tighten the plug to 24 N·m (18 lb ft)

28. Using J 35467 , install a NEW clutch housing hole plug (1) into the clutch housing.

Tighten
Tighten the bolt to 39 N·m (29 lb ft).

29. Using J 44731 , install a NEW input shaft seal (1) to the clutch housing.
30. Align and install the main shaft bearing oil slinger (4) to the output shaft.
31. Grease and install the locking ball (3) to the output shaft.
32. Align and install the vehicle speed sensor drive gear (2) to the output shaft.
33. Install a NEW rear output shaft rear bearing spacer (1) to the output shaft.
34. Apply an approved sealer to the interface of either case.
35. Install the rear extension housing (2) to the rear case.
36. Install the rear extension housing to rear case retaining bolts (1).

Tighten
Tighten the bolts to 29 N·m (21 lb ft)

37. Install a NEW select shift lever retainer (3), the damper (2) and shift lever rod universal joint (1) into the end of the shift selector.
38. Install the shift lever pin (1) to the select shift lever rod universal joint (2).
39. With a suitable tool, rotate the shift lever retainer (2) backward.
40. Stake the retainer (2) in place using pliers and 2 roll pins held in place with assembly lube.
41. Install the propshaft flange (1) to the output shaft.
42. Grease and install a NEW propshaft flange thrust washer (2) to the output shaft.
43. Install a NEW propshaft flange nut (3) to the output shaft.

### Preload Adjustment Procedure

1. Shift the transmission into any gear.
2. Attach DT-47735 (1) to the output flange.
3. Hold DT-47735 in order to prevent the output flange from rotating. Install and tighten the output flange nut. Tighten until the looseness is minimum.
4. Verify looseness by shaking the output shaft longitudinally.
5. Remove DT-47735 from the output flange.
6. Shift the transmission into NEUTRAL.
7. Rotate the output flange several times in order to break in the gears, synchronizers and bearings.
8. Measure the rotational torque/drag torque of the output flange by using a suitable tool (1). Record this initial rotational torque measurement as value A.
9. Attach DT-47735 (1) to the output flange.
10. Shift the transmission into any gear.
11. Tighten the propshaft flange to output shaft retaining nut.

Tighten
Tighten the nut 220-565 N·m (162-417 lb ft).

12. Remove the DT-47735 from the output flange.
13. Shift the transmission into NEUTRAL.
14. Rotate the output flange several times in order to seat the bearings.
15. Measure the rotational torque/drag torque of the output flange by using a suitable tool. Record this measurement as value B.
16. Subtract value A from value B. Verify that the resulting measurement is within the specified range.

Specification
The rotational torque specification is.45-1.35 N·m (4-12 lb in).

17. Repeat the previous steps until you have confirmed that the rotational torque specification is reached then stake the nut in place. If the rotational torque requirement has been exceeded, replace the output shaft spacer and repeat steps 2-16.
18. Install the output sensor (1) to the extension housing.
19. Install the output sensor to extension housing retaining bolt (2).

Tighten
Tighten the bolt to 8 N·m (71 lb in).

20. Install a NEW backup lamp washer (1) to the backup switch.
21. Install the backup switch to the extension housing.

Tighten
Tighten the switch to 44 N·m (32 lb ft).

22. Install the NEW gaskets (2), drain plug (3) and fill plug (1).

• | Install the drain plug (3) to the rear case.

Tighten
Tighten both plugs to 37 N·m (27 lb ft).

• | Install the fill plug (1) to the intermediate case.

Tighten
Tighten both plugs to 37 N·m (27 lb ft).