Log In
Search suggestions

    My Vehicles

    1992 Cadillac Deville 4.9L SFI 8cyl

    My Store

    405 N COLLEGE ST
    (479) 443-4043

    CLOSED Open at 7:30 AM

    SAVE 20% + GET A $10 GIFT CARD ON ONLINE SHIP-TO-HOME ORDERS OVER $100.

    Use Code: FALLBACK

    See Details

    Chrysler Full-Size Trucks 1967-1988 Repair Guide

    Transmission

    Print

    REMOVAL & INSTALLATION



    2-Wheel Drive Models
    3-SPEED
    1. Raise and support the vehicle.
    2.  
    3. Drain lubricant from the transmission.
    4.  
    5. Disconnect and matchmark the driveshaft. On the sliding spline type, disconnect driveshaft at the rear universal joint, then carefully pull the shaft yoke out of the transmission extension housing. Do not nick or scratch splines.
    6.  
    7. Disconnect the gearshift control rods and speedometer cable.
    8.  
    9. Remove the backup light switch, if so equipped.
    10.  
    11. Support the engine.
    12.  
    13. Remove the crossmember and rubber insulator on 875 and later models with A-390 transmission. On all other models, unbolt the insulator or mount from the crossmember. Support the transmission with a jack.
    14.  
    15. Remove transmission-to-clutch housing bolts.
    16.  
    17. Slide transmission rearward until the pinion shaft clears the clutch completely, then lower the transmission from vehicle.
    18.  

    To install:
    1. Before inserting transmission driveshaft into clutch, make sure the clutch housing bore, disc and face are aligned. Make sure you grease the inner end of the pinion shaft pilot bushing and the pinion bearing retainer pilot, for the clutch release sleeve using lubricant .
    2.  
    3. Slide the transmission forward until the pinion shaft enters the clutch completely, then push the transmission forward all the way.
    4.  
    5. Install the transmission-to-clutch housing bolts. Tighten the bolts to 36 ft. lbs. (67 Nm).
    6.  
    7. Install the crossmember and rubber insulator on 875 and later models with A-390 transmission. On all other models, bolt the insulator or mount to the crossmember.
    8.  
    9. Install backup light switch if so equipped.
    10.  
    11. Connect gearshift control rods and speedometer cable.
    12.  
    13. Connect the driveshaft. On the sliding spline type, carefully slide the shaft yoke into the transmission extension housing. Do not nick or scratch splines. Connect the driveshaft at the rear universal joint.
    14.  
    15. Fill the transmission with lubricant.
    16.  
    17. Adjust shift linkage.
    18.  
    19. Lower the vehicle, then road test.
    20.  

    4-SPEED



    1. Shift transmission into any gear.
    2.  
    3. Raise and support the vehicle with jack stands.
    4.  
    5. Disconnect universal joint matchmark parts, and loosen yoke retaining nut. Drain lubricant.
    6.  
    7. Disconnect the parking brake (if so equipped), along with the speedometer cables and back-up lamp switch at transmission.
    8.  
    9. Remove the lever retainer by pressing down, rotating retainer counterclockwise slightly, then releasing.
    10.  
    11. Remove the lever and its springs and washers.
    12.  
    13. Support the rear of the engine and remove the crossmember. Remove transmission to clutch bell housing retaining bolts and pull transmission rearward until drive pinion clears clutch, then remove transmission.
    14.  

    To install:
    1. Place lubricant in the pinion shaft pilot bushing, taking care not to get any grease on flywheel face.
    2.  
    3. Align the clutch disc and backing plate with a spare drive pinion shaft or clutch aligning tool, then carefully install transmission.
    4.  
    5. Install the transmission to the bell housing with bolts, tightening to 36 ft. lbs. (67 Nm) torque. Replace the crossmember.
    6.  
    7. Install the gear shift lever, shift into any gear and tighten yoke nut to 95-105 ft. lbs. (128-142 Nm) torque.
    8.  
    9. Install the universal joint, speedometer cable and brake cable.
    10.  
    11. Adjust the clutch.
    12.  
    13. Install the transmission drain plug and fill transmission with lubricant. Make sure the truck is level.
    14.  
    15. Remove the jack stands and carefully lower the vehicle, then road test.
    16.  

    5-SPEED



    1. Raise and support the truck.
    2.  
    3. Remove the skid plate, if any. Drain lubricant from the transmission and transfer case.
    4.  
    5. Disconnect the speedometer cable.
    6.  
    7. Disconnect and matchmark the driveshaft. Suspend the shaft from a convenient place; do not allow it to hang free.
    8.  
    9. Disconnect the back-up light switch.
    10.  
    11. Support the engine.
    12.  
    13. Support the transmission.
    14.  
    15. Remove the transmission crossmember.
    16.  
    17. Remove the transmission-to-clutch housing bolts.
    18.  
    19. Slide the transmission rearward until the mainshaft clears the clutch disc.
    20.  
    21. Lower and remove the transmission.
    22.  

    To install:
    1. The transmission pilot bushing in the end of the crankshaft requires high-temperature grease. Multipurpose grease should be used. Do not lubricate the end of the mainshaft, clutch splines, or clutch release levers.
    2.  
    3. Raise and position the transmission.
    4.  
    5. Slide the transmission forward until the mainshaft enters the clutch disc, then push it all the way forward.
    6.  
    7. Install the transmission-to-clutch housing bolts, then tighten to 36 ft. lbs. (67 Nm).
    8.  
    9. Install the transmission crossmember.
    10.  
    11. Connect the back-up light switch.
    12.  
    13. Connect the front driveshaft.
    14.  
    15. Connect the speedometer cable.
    16.  
    17. Install the skid plate, if any. Fill the transmission.
    18.  
    19. Lower the truck.
    20.  

    4WD Models
    3 AND 4-SPEEDS
    1. Raise and support the truck.
    2.  
    3. Remove the skid plate, if any. Drain lubricant from the transmission and transfer case.
    4.  
    5. Disconnect the speedometer cable.
    6.  
    7. Disconnect and matchmark the front and rear driveshafts. Suspend each shaft from a convenient place; do not allow them to hang free.
    8.  
    9. Disconnect the shift rods at the transfer case. On 4-speed transmissions, remove the shift lever retainer by pressing down and turning it counterclockwise. Remove the shift lever springs and washers.
    10.  
    11. Matchmark the driveshaft and rear U-joints then remove the driveshaft.
    12.  
    13. Support the transfer case.
    14.  
    15. Remove the extension-to-transfer case mounting bolts.
    16.  
    17. Move the transfer case rearward to disengage the front input shaft spline.
    18.  
    19. Lower and remove the transfer case.
    20.  
    21. Disconnect the back-up light switch.
    22.  
    23. Support the engine.
    24.  
    25. Support the transmission.
    26.  
    27. Remove the transmission crossmember.
    28.  
    29. Remove the transmission-to-clutch housing bolts.
    30.  
    31. Slide the transmission rearward until the mainshaft clears the clutch disc.
    32.  
    33. Lower and remove the transmission.
    34.  

    To install:
    1. The transmission pilot bushing in the end of the crankshaft requires high-temperature grease. Multipurpose grease should be used. Do not lubricate the end of the mainshaft, clutch splines, or clutch release levers.
    2.  
    3. Raise and position the transmission.
    4.  
    5. Slide the transmission forward until the mainshaft enters the clutch disc, then push it all the way forward.
    6.  
    7. Install the transmission-to-clutch housing bolts, then tighten to 36 ft. lbs. (67 Nm).
    8.  
    9. Install the transmission crossmember.
    10.  
    11. Connect the back-up light switch.
    12.  
    13. Raise and position the transfer case.
    14.  
    15. Move the transfer case forwards to disengage the front input shaft spline.
    16.  
    17. Install the extension-to-transfer case mounting bolts, then tighten to 36 ft. lbs. (67 Nm).
    18.  
    19. Install the rear driveshaft.
    20.  
    21. Connect the shift rods at the transfer case. On 4-speed transmissions, install the shift lever retainer by pressing down and turning it clockwise. Install the shift lever springs and washers.
    22.  
    23. Connect the front driveshafts.
    24.  
    25. Connect the speedometer cable.
    26.  
    27. Install the skid plate, if any. Fill the transmission and transfer case.
    28.  
    29. Adjust the gearshift linkage on 3-speed transmissions.
    30.  
    31. Lower the truck.
    32.  

    OVERHAUL



    A-833 Overdrive-4 Disassembly

    See Figures 1 and 2



    Click image to see an enlarged view

    Fig. Fig. 1: A-833 hand lever removal



    Click image to see an enlarged view

    Fig. Fig. 2: A-833 exploded view

    The A-833 Overdrive-4 Speed transmission is a four speed unit with all forward gears synchronized. 3rd gear is direct, while the 4th gear is the overdrive ratio. Lubricant capacity is approximately 7 pints.

    GEARSHIFT HOUSING AND MECHANISM
    1. If available, mount the transmission in a repair stand.
    2.  
    3. Disconnect the gearshift control rods from the shift control levers and the transmission operating levers.
    4.  
    5. Remove the two gearshift control housing mounting bolts.
    6.  
    7. Remove the gearshift control housing from the transmission extension housing or mounting bracket (if so equipped).
    8.  
    9. Remove the gearshift control housing mounting bracket bolts, then remove the bracket (if so equipped).
    10.  
    11. Remove the back-up light switch (if so equipped).
    12.  
    13. Remove the output companion flange nut and washer, if used, then pull the flange from the mainshaft (output shaft).
    14.  
    15. Remove the gearshift housing-to-transmission case attaching bolts.
    16.  
    17. With all the levers in the neutral detent position, pull the housing out and away from the case.
    18.  

    If the 1st/2nd, or 3rd/4th shift forks remain in engagement with the synchronizer sleeves, move the sleeves and remove forks from the case.

    1. Remove the nuts, lock washers and flat washers that hold the 1st/2nd, and 3rd/4th speed shift operating levers to the shafts.
    2.  
    3. Disengage the shift levers from the flats on the shafts and remove the levers. Remove the E-ring on the overdrive 4-speed.
    4.  

    EXTENSION HOUSING, MAINSHAFT AND MAIN DRIVE PINION
    1. Remove the bolt and retainer holding the speedometer pinion adapter in the extension housing, then remove the pinion adapter.
    2.  
    3. Remove the bolts attaching the extension housing to the transmission case.
    4.  
    5. Rotate the extension housing on the output shaft to expose the rear of the countershaft. Install one bolt to hold the extension in place.
    6.  
    7. Drill a hole in the countershaft extension plug at the front of the case.
    8.  
    9. Reaching through this hole, push the countershaft to the rear to expose the Woodruff key; when exposed, remove it. Push the countershaft forward against the expansion plug, and using a brass drift, tap the countershaft forward until the expansion plug is removed.
    10.  
    11. Using a countershaft arbor, push the countershaft out the rear of the case, but don't let the countershaft washers fall out of position. Lower the cluster gear to the bottom of the transmission case.
    12.  
    13. Remove the bolt and rotate the extension back to the normal position.
    14.  
    15. Remove the drive pinion attaching bolts and slide the retainer and gasket from the pinion shaft, then pry the pinion or seal from the retainer. When installing the new seal, don't nick or scratch the seal bore in the retainer or the surface on which the seal bottoms.
    16.  
    17. Using a brass drift, tap the pinion and bearing assembly forward and remove it through the front of the case.
    18.  
    19. Slide the 3rd and overdrive synchronizer sleeve slightly forward, slide the reverse idler gear to the center of its shaft, and tap the extension housing rearward. Slide the housing and mainshaft assembly out and away from the case.
    20.  
    21. Remove the snapring holding the 3rd and overdrive synchronizer clutch gear and sleeve assembly to the mainshaft, then remove the synchronizer assembly.
    22.  
    23. Slide the overdrive gear and stop ring off the mainshaft. Using pair of long-nose pliers, compress the snapring holding the mainshaft bearing in the extension housing. With it compressed, pull the mainshaft assembly and bearing out of the extension housing.
    24.  
    25. Remove the snapring retains the mainshaft bearing on the shaft. The bearing is removed by inserting steel plates on the front side of the 1st speed gear, then pressing the mainshaft through the bearing being careful not to damage the gear teeth.
    26.  
    27. Remove the bearing, retainer ring, 1st speed gear and stop ring from the shaft.
    28.  
    29. Remove the snapring. Remove the 1st and 2nd clutch gear and sleeve assembly from the mainshaft.
    30.  
    31. Remove the drive pinion bearing inner snapring, then using an arbor press, remove the bearing. Remove the snapring and bearing rollers from the cavity in the drive pinion.
    32.  
    33. Remove the countershaft gear from the bottom of the case, then remove the arbor, needle bearings, thrust washers and spacers from the center of the countershaft gear.
    34.  
    35. Remove the reverse gearshift lever detent spring retainer, gasket, plug, and detent ball spring from the rear of the case.
    36.  
    37. The reverse idler gear shaft is a tight fit in the case and will have to be pressed out.
    38.  
    39. If there is oil leakage visible around the reverse gearshift lever shaft, push the lever shaft in and remove it from the case. Remove the detent ball from the bottom of the transmission case and remove the shift fork from the shaft and detent plate.
    40.  

    A-833 Overdrive-4 Assembly
    REVERSE SHAFT

    See Figures 3 and 4

    Follow the first four steps only if you removed the reverse shaft in the disassembly procedure.

    1. Install a new oil seal O-ring on the lever shaft and coat the shaft with grease; insert it into its bore and install the reverse fork in the lever.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 3: A-833 gear, shaft and lever

    1. Install the reverse detent spring and gasket; insert the ball and spring, then install the plug and gasket.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 4: A-833 reverse idler shaft removal

    1. Place the reverse idler gear shaft in position in the end of the case and drive it in far enough to position the reverse idler gear on the protruding end of the shaft with the fork slot toward the rear. While doing this, engage the slot with the reverse shift fork.
    2.  
    3. With the reverse idler gear correctly positioned, drive the reverse gear shaft into the case far enough to install the Woodruff key. Drive the shaft in flush with the end of the transmission case. Install the back-up light switch and gasket.
    4.  

    COUNTERSHAFT GEAR AND DRIVE PINION
    1. Coat the inside bore of the countershaft gear with a thin film of grease and install the roller bearing spacer with an arbor, into the gear; center the spacer and arbor.
    2.  
    3. Install the roller bearings and a spacer ring on each end.
    4.  
    5. Replace worn thrust washers; coat the new ones with grease and install them over the arbor with the tang side toward the case boss.
    6.  
    7. Install the countershaft assembly into the case and allow the gear assembly to sit on the bottom of the case so that the thrust washers won't come out of position.
    8.  
    9. Press the drive pinion bearing on the pinion shaft. Make sure the outer snapring groove is toward the front end and the bearing is seated against the shoulder on the gear.
    10.  
    11. Install a new snapring on the shaft to hold the bearing in place; make sure the snapring is seated and that there is minimum end-play. There are several snapring thicknesses available for adjustment.
    12.  
    13. Place the pinion shaft in a soft-jawed vise and install the roller bearings in the shaft cavity.
    14.  

    Coat them with grease and install the bearing retaining snapring.

    1. Install a new oil seal in the bore.
    2.  

    EXTENSION HOUSING BUSHING
    1. Remove the yoke seal from the extension housing.
    2.  
    3. Drive out the old bushing and drive in a new one, aligning the oil hole in the bushing with the slot in the housing.
    4.  
    5. Place a new seal in the opening of the extension housing and then drive it into place.
    6.  

    MAINSHAFT
    1. Place a stop ring flat on a bench followed by the clutch gear and sleeve; drop the struts in their slots and snap in a strut spring placing the tang inside one strut. Install the 2nd strut spring tang in a different strut after turning the assembly over.
    2.  
    3. Slide the 2nd speed gear over the mainshaft with the synchronizer cone toward the rear and down against the shoulder on the shaft.
    4.  
    5. Slide the 1st and 2nd gear synchronizer assembly including stop rings with lugs indexed in the hub slots, over the mainshaft down against the 2nd gear cone and hold it there with a new snapring. Slide the next snapring over the shaft and index the lugs into the clutch hub slots.
    6.  
    7. Slide the 1st speed gear with the synchronizer cone toward the clutch sleeve just installed over the mainshaft and into position against the clutch sleeve gear.
    8.  
    9. Install the mainshaft bearing retaining ring followed by the mainshaft rear bearing; press the bearing down into position and install a new snapring to secure it. There are several snapring thicknesses available for minimum end-play.
    10.  
    11. Install the partially assembled mainshaft into the extension housing far enough to engage the bearing retaining ring in the slot in the extension housing. Compress the ring with pliers so that the mainshaft ball bearing can move in and bottom against its thrust shoulder in the extension housing. Release the ring and make sure that it is seated.
    12.  
    13. Slide the overdrive gear over the mainshaft with the synchronizer cone toward the front followed by the gear's snapring.
    14.  
    15. Install the 3rd/overdrive gear synchronizer clutch gear assembly on the mainshaft against the overdrive gear. Make sure to index the rear stop ring with the clutch gear struts.
    16.  
    17. Install the snapring and position the front stop ring over the clutch gear again lining up the ring lugs with the struts; coat a new extension gasket with grease and place it in position.
    18.  
    19. Slide the reverse idler gear to the center of its shaft and move the 3rd/overdrive synchronizer as far forward as possible without losing the struts.
    20.  
    21. Insert the mainshaft assembly in the case tilting it as necessary. Place the 3rd/overdrive sleeve in the neutral detent.
    22.  
    23. Rotate the extension on the mainshaft to expose the rear of the countershaft and install one bolt to hold it in position.
    24.  
    25. Install the drive pinion and bearing assembly through the front of the case and position it in the front bore. Install the outer snapring in the bearing groove and tap lightly into place. If it doesn't bottom easily, check to see if a strut, pinion roller or stop ring is out of position.
    26.  
    27. Turn the transmission upside down while holding the countershaft gear to prevent damage. Then lower the countershaft gear assembly into position making sure that the teeth mesh with the drive pinion gear.
    28.  
    29. Start the countershaft into the bore at the rear of the case and push until it is in about halfway; then install the Woodruff key and push it in until it is flush with the rear of the case.
    30.  
    31. Rotate the extension back to normal position and install the bolts; turn the transmission upright and install the drive pinion bearing retainer and gasket. Coat the threads with sealing compound and tighten the attaching bolts to 19 ft. lbs. (40 Nm).
    32.  
    33. Install a new expansion plug in its bore.
    34.  

    GEARSHIFT HOUSING AND MECHANISM
    1. Install the interlock levers on the pivot pin and secure with the E-ring. Install the spring with a pair of pliers.
    2.  
    3. Grease and install new O-ring seals on both shift shafts; grease the housing bores and push the shafts through.
    4.  
    5. Install the operating levers and tighten the retaining nuts to 6 ft. lbs. (24 Nm); make sure the 3rd-overdrive lever points down.
    6.  
    7. Rotate each shift shaft fork bore straight up and install the 3rd/overdrive shift fork in its bore and under both interlock levers.
    8.  
    9. Position both synchronizer sleeves in neutral and place the 1st and 2nd gear shift fork in the groove of the 1st/2nd gear synchronizer sleeve. Slide the reverse idler gear to neutral. Turn the transmission on its right side and place the gearshift housing gasket in place holding it there with grease. Install the reverse detent ball and spring into the case bore.
    10.  
    11. As the shift housing is lowered in place, guide the 3rd/overdrive shift fork into its synchronizer groove then lead the shaft of the 1st/2nd shift lever.
    12.  
    13. Raise the interlock lever with a screwdriver to allow the 1st/2nd shift fork to slip under the levers. The shift housing will now seat against the case.
    14.  
    15. Install the bolts lightly and shift through all the gears to check for proper operation.
    16.  
    17. The reverse shift lever and the 1st/2nd gear shift lever have cam surfaces which mate in reverse position to lock the 1st/2nd lever, the fork and synchronizer in the neutral position.
    18.  
    19. To check for proper operation, put the transmission in reverse, and, while turning the input shaft, move the 1st/2nd lever in each direction. If it locks up or becomes harder to turn, select a new shift lever size with more or less clearance. If there is too little cam clearance, it will be difficult or impossible to shift into reverse.
    20.  
    21. Grease the reverse shaft, install the operating lever and nut, install the speedometer drive pinion gear and adapter, making sure the range number is in the straight down position.
    22.  

    New Process 305 Disassembly

    See Figures 5 and 6

    SHIFT COVER AND PARKING BRAKE
    1. Mount the transmission in a holding fixture. Remove the parking brake assembly, if one is installed.
    2.  
    3. Shift the gears into neutral by replacing the gear shift lever temporarily, or by using a small prytool.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 5: NP-435 exploded view

    1. Remove the cover screws, the 2nd screw from the front on each side is shouldered with a split washer for installation alignment.
    2.  
    3. While lifting the cover, rotate slightly counterclockwise to provide clearance for the shift levers. Remove the cover.
    4.  
    5. Lock the transmission in two gears and remove the output flange nut, the yoke, and the parking brake drum as a unit assembly.
    6.  

    The drum and yoke are balanced and unless replacement of parts are required, it is recommended that the drum and yoke be removed as an assembly.

    1. Remove the speedometer drive gear pinion and the mainshaft rear bearing retainer.
    2.  
    3. Before removal and disassembly of the drive pinion and mainshaft, measure the end-play between the synchronizer stop ring and the 3rd gear. Clearance should be within 0.05-0.07 in. (1.27-1.78mm). If necessary, add corrective shims during assembly.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 6: Measure the synchronizer end-play and record it

    Record this reading for reference during assembly.

    1. Remove the drive pinion bearing retainer.
    2.  
    3. Rotate the drive pinion gear to align the space in the pinion gear clutch teeth with the countershaft drive gear teeth. Remove the drive pinion gear and the tapered roller bearing from the transmission by pulling on the pinion shaft, and rapping the face of the case lightly with a brass hammer.
    4.  
    5. Remove the snapring, washer, and the pilot roller bearings from the recess in the drive pinion gear.
    6.  
    7. Place a brass drift in the front center of the mainshaft and drive the shaft rearward.
    8.  
    9. When the mainshaft rear bearing has cleared the case, remove the rear bearing and the speedometer drive gear with a suitable gear puller.
    10.  
    11. Move the mainshaft assembly to the rear of the case and tilt the front of the mainshaft upward.
    12.  
    13. Remove the roller type thrust washer.
    14.  
    15. Remove the synchronizer and stop rings separately.
    16.  
    17. Remove the mainshaft assembly.
    18.  
    19. Remove the reverse idler lockscrew and lockplate.
    20.  
    21. Using a brass drift held at an angle, drive the idler shaft to the rear while pulling.
    22.  
    23. Lift the reverse idler gear out of the case.
    24.  

    If the countershaft gear does not show signs of excessive side-play or end-play and the teeth are not badly worn or chipped, it may not be necessary to replace the countershaft gear.

    1. Remove the bearing retainer at the rear end of the countershaft. The bearing assembly will remain with the retainer.
    2.  
    3. Tilt the cluster gear assembly and work it out of the transmission case.
    4.  
    5. Remove the front bearings from the case with a suitable driver.
    6.  

    MAINSHAFT



    1. Remove the clutch gear snapring.
    2.  
    3. Remove the clutch gear, the synchronizer outer stop ring-to-3rd gear shim, and the 3rd gear.
    4.  
    5. Remove the special split lockring with two screwdrivers. Remove the 2nd gear and synchronizer.
    6.  
    7. Remove the 1st/reverse sliding gear.
    8.  
    9. Drive the old seal out of the bearing retainer.
    10.  
    11. Place the mainshaft in a soft jawed vise with the rear end up.
    12.  
    13. Install the 1st/reverse gear. Be sure the two spline springs, if used, are in place inside the gear as the gear is installed on the shaft.
    14.  
    15. Place the mainshaft in a soft/jawed vise with the front end up.
    16.  
    17. Assemble the 2nd speed synchronizer spring and synchronizer brake on the 2nd gear. Secure the brake with a snapring making sure that the snapring tangs are away from the gear.
    18.  
    19. Slide the 2nd gear on the front of the mainshaft. Make sure that the synchronizer brake is toward the rear. Secure the gear to the shaft with the two piece lockring. Install the 3rd gear.
    20.  
    21. Install the shim between the 3rd gear and the 3rd/4th synchronizer stop ring. Refer to the measurements of end-play made during disassembly to determine if additional shims are needed.
    22.  

    The exact determination of end-play must be made after the complete assembly of the mainshaft and the main drive pinion is installed in the transmission case.

    REVERSE IDLER GEAR



    Do not disassemble the reverse idler gear. If it is no longer serviceable, replace the assembly complete with the integral bearings.

    COVER AND SHIFT FORK UNIT



    See Figures 7 and 8

    The cover and shift fork assembly should be disassembled only if inspection shows worn or damaged parts, or if the assembly is not working properly.

    1. Remove the roll pin from the 1st/2nd shift fork and the shift gate with a screw extractor.
    2.  

    A square type or a closely wound spiral screw extractor mounted in a tap is preferable for this operation.

    1. Move the 1st/2nd shift rail forward and force the expansion plug out of the cover. Cover the detent ball access hole in the cover with a cloth to prevent it from flying out. Remove the rail, fork, and gate from the cover.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 7: NP-435 cover and shift fork assembly view

    1. Remove the 3rd/4th shift rail, then the reverse rail in the manner outlined in Steps 1 and 2 above.
    2.  
    3. Compress the reverse gear plunger and remove the retaining clip. Remove the plunger and spring from the gate.
    4.  
    5. Install the spring on the reverse gear plunger and hold it in the reverse shift gate. Compress the spring in the shift gate and install the retaining clip.
    6.  
    7. Insert the reverse shift rail in the cover, place the detent ball and spring in position. Depress the ball and slide the shift rail over it.
    8.  
    9. Install the shift gate and fork on the reverse shift rail. Install a new roll pin in the gate and the fork.
    10.  
    11. Place the reverse fork in the neutral position.
    12.  
    13. Install the two interlock plungers in their bores.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 8: Exploded view of the shift fork tower assembly

    1. Insert the interlock pin in the 3rd/4th shift rail. Install the shift rail in the same manner as the reverse shift rail.
    2.  
    3. Install the 1st/2nd shift rail in the same manner as outlined above. Make sure the interlock plunger is in place.
    4.  
    5. Check the interlocks by shifting the reverse shift rail into the Reverse position. It should be impossible to shift the other rails with the reverse rail in this position.
    6.  
    7. If the shift lever is to be installed at this point, lubricate the spherical ball seat and position the cap.
    8.  
    9. Install the back-up light switch.
    10.  
    11. Install new expansion plugs in the bores of the cover shift rail holes and cover. Install the rail interlock hole plug.
    12.  

    DRIVE PINION AND BEARING RETAINER



    See Figures 9 and 10

    1. Remove the tapered roller bearing from the pinion shaft with a suitable tool.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 9: Drive pinion gear assembly

    1. Remove the snapring, washer, and the pilot rollers from the gear bore, if they have not been previously removed.
    2.  
    3. Pull the bearing race from the front bearing retainer with a suitable puller.
    4.  
    5. Remove the pinion shaft seal with a suitable tool.
    6.  
    7. Position the drive pinion in an arbor press.
    8.  
    9. Place a wood block on the pinion gear and press it into the bearing until it contacts the bearing inner race.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 10: Installing the pinion bearing

    1. Coat the roller bearings with a light film of grease to hold the bearings in place, and insert them in the pocket of the drive pinion gear.
    2.  
    3. Install the washer and snapring.
    4.  
    5. Press a new seal into the bearing retainer. Make sure that the lip of the seal is toward the mounting surface.
    6.  
    7. Press the bearing race into the retainer.
    8.  

    New Process 305 Assembly
    COUNTERSHAFT
    1. Press the front countershaft roller bearings into the case until the cage is flush with the front of the transmission case. Coat the bearings with a light film of grease.
    2.  
    3. Place the transmission with the front of the case facing down. If uncaged bearings are used, hold the loose rollers in place in the cap with a light film of grease.
    4.  
    5. Lower the countershaft assembly into the case placing the thrust washer tangs in the case slots, and inserting the front end of the shaft into the bearing.
    6.  
    7. Place the roller thrust bearing and race on the rear end of the countershaft. Hold the bearing in place with a light film of grease.
    8.  
    9. While holding the gear assembly in alignment, install the rear bearing retainer gasket, retainer, and bearing assembly. Install and tighten the cap screws.
    10.  

    REVERSE IDLER GEAR
    1. Position the reverse idler gear and bearing assembly in the case.
    2.  
    3. Align the idler shaft so that the lockplate groove in the shaft is in position to install the lockplate.
    4.  
    5. Install the lockplate, washer, and cap screw.
    6.  
    7. Make sure the reverse idler gear turns freely.
    8.  

    MAINSHAFT AND DRIVE PINION
    1. Lower the rear end of the mainshaft assembly into the case, holding the 1st gear on the shaft. Maneuver the shaft through the rear bearing opening.
    2.  

    With the mainshaft assembly moved to the rear of the case, be sure the 3rd/4th synchronizer and shims remain in position.

    1. Install the roller type thrust bearing.
    2.  
    3. Place a wood block between the front of the case and the front of the mainshaft.
    4.  
    5. Install the rear bearing on the mainshaft by carefully driving the bearing onto the shaft and into the case, with the snapring flush against the case.
    6.  
    7. Install the drive pinion shaft and bearing assembly. Make sure that the pilot rollers remain in place.
    8.  
    9. Install the spacer and speedometer drive gear.
    10.  
    11. Install the rear bearing retainer and gasket.
    12.  
    13. Place the drive pinion bearing retainer over the pinion shaft, without the gasket.
    14.  
    15. Hold the retainer tight against the bearing and measure the clearance between the retainer and the case with a feeler gauge.
    16.  

    End-play in the following steps below allows for normal expansion of parts during operation, preventing seizure and damage to bearings, gears, synchronizers, and shafts.

    1. Install a gasket shim pack 0.010-0.015 in. (0.254-0.381mm) thicker than measured clearance between the retainer and case to obtain the required 0.007-0.017 in. (0.178-0.432mm) pinion shaft end-play. Tighten the front retainer bolts and recheck the end-play.
    2.  
    3. Check the synchronizer end-play clearance, 0.05-0.07 in. (1.27-1.78mm) after all mainshaft components are in position and properly tightened. Two sets of feeler gauges are used to measure the clearance. Care should be used to keep both gauges as close as possible to both sides of the mainshaft for best results.
    4.  

    In some cases, it may be necessary to disassemble the mainshaft and change the thickness of the shims to keep the end-play clearance within the specified limits, 0.050-0.070 in. (1.27-1.78mm). Shims are available in two thicknesses.

    1. Install the speedometer drive pinion.
    2.  
    3. Install the yoke flange, drum, and drum assembly.
    4.  
    5. Place the transmission in two gears at once, and tighten the yoke flange nut.
    6.  
    7. Shift the gears and/or synchronizers into all gear positions and check for free rotation.
    8.  

    COVER
    1. Cover all transmission components with a film of transmission oil to prevent damage during start up after initial lubricant fill-up.
    2.  
    3. Move the gears to the neutral position.
    4.  
    5. Place a new cover gasket on the transmission case, and lower the cover over the transmission.
    6.  
    7. Carefully engage the shift forks into their proper gears. Align the cover.
    8.  
    9. Install a shouldered alignment screw with split washer in the screw hole 2nd from the front of the cover. Try out gear operation by shifting through all ranges. Make sure everything moves freely.
    10.  
    11. Install the remaining cover screws.
    12.  

    New Process 445 4-Speed Disassembly

    See Figure 11



    Click image to see an enlarged view

    Fig. Fig. 11: Parts locations of an NP-445

    DRIVE PINON
    1. Place the transmission in a holding fixture and drain the lubricant.
    2.  
    3. Shift the transmission gears into neutral. Remove the gearshift cover attaching bolts. Note that the two bolts opposite the tower are shouldered to properly position the cover. Lift the cover straight up and remove.
    4.  
    5. Lock the transmission in two gears at once and remove the mainshaft nut and yoke.
    6.  
    7. Loosen and remove the extension housing bolts. Remove the mainshaft extension housing and the speedometer drive pinion.
    8.  
    9. Remove the bolts from the drive pinion front bearing retainer, then pull the bearing retainer and gasket off.
    10.  
    11. Rotate the drive pinion gear to align the pinion gear flat with the countershaft drive gear teeth. Remove the drive pinion gear and the tapered roller bearing from the transmission.
    12.  

    MAINSHAFT
    1. Remove the mainshaft thrust bearing.
    2.  
    3. Push the mainshaft assembly to the rear of the transmission and tilt the front of the mainshaft up.
    4.  
    5. Remove the mainshaft assembly from the transmission case.
    6.  

    REVERSE IDLER GEAR
    1. Remove the reverse idler lockscrew and lockplate.
    2.  
    3. Using a suitable size brass drift, carefully drive the reverse idler shaft out the REAR of the case.
    4.  


    WARNING
    Do not attempt to drive the reverse idler shaft forward. This will damage the transmission case and the reverse idler shaft.

    COUNTERSHAFT
    1. Remove the countershaft rear bearing retainer.
    2.  
    3. Slide the countershaft to the rear, then up and out of the case.
    4.  
    5. Drive the countershaft forward, out of the bearing and the case.
    6.  

    New Process 445 4-Speed Component Disassembly
    MAINSHAFT
    1. Place the mainshaft in a soft-jawed vise with the front end up.
    2.  
    3. Lift the 3rd-4th synchronizer and high speed clutch off the mainshaft. Remove the 3rd gear.
    4.  
    5. Remove the 2nd gear snapring. Lift off the thrust washer. Remove the 2nd gear.
    6.  
    7. Remove the low-speed synchronizer and clutch gear.
    8.  
    9. Install the mainshaft in the vise rear end up.
    10.  
    11. Remove the tapered bearing from the shaft with a suitable gear puller.
    12.  
    13. Remove the 1st gear snapring and thrust washer. Remove the 1st gear.
    14.  

    To install:
    1. Lubricate all parts with transmission lubricant prior to assembly.
    2.  
    3. Place the mainshaft in a soft-jawed vise with the rear end up.
    4.  
    5. Slide the 1st gear over the mainshaft, with the clutch gear facing down. Install the thrust washer and snapring.
    6.  
    7. Install the reverse gear over the end of the mainshaft with the fork groove facing down.
    8.  
    9. Install the mainshaft rear bearing on the mainshaft with a sleeve of suitable size. Press the bearing on its inner race.
    10.  
    11. Install the mainshaft in the vise with the front end facing up. Install the 1st-reverse synchronizer.
    12.  
    13. Install the 2nd gear on the mainshaft.
    14.  
    15. Install the keyed thrust washer, ground side toward the 2nd gear and secure with the snapring.
    16.  
    17. Install the 3rd gear and one shim on the mainshaft.
    18.  
    19. Install the 3rd-4th synchronizer over the mainshaft. Make sure that the slotted end of the clutch gear is positioned toward the 3rd gear.
    20.  

    COVER AND SHIFT FORK

    The cover and shift fork assembly should be disassembled only if inspection shows worn or damaged parts, or if the assembly is not working properly.

    1. Remove the roll pin from the 1st/2nd shift fork and the shift gate. Use a square-type or spiral wound screw extractor mounted in a tap handle for these operations.
    2.  
    3. Move the 1st/2nd shift rail rearward and force the expansion plug out of the cover. Cover the detent ball access hole in the cover with a cloth to prevent it from flying out. Remove the rail fork, and gate from the cover.
    4.  
    5. Remove the 3rd/4th shift rail, then the reverse rail in the manner.
    6.  
    7. Compress the reverse gear plunger and remove the retaining clip. Remove the plunger and spring from the gate.
    8.  

    To install:
    1. Apply a thin film of grease on the interlock slugs and slide them into the openings in the shift rail supports.
    2.  
    3. Install the reverse shift rail through the reverse shift fork plate and the reverse shift fork.
    4.  
    5. Secure the reverse shift plate and the shift fork with the roll pins. Install the interlock pin in the 3rd/4th shift rail. Hold in place with a thin film of grease.
    6.  
    7. Slide the 3rd/4th shift rail into the rail support from the rear of the cover. Slide the rail through the 3rd/4th shift fork and detent ball and spring. Secure the 3rd/4th shift fork with the roll pin.
    8.  
    9. Install the interlock pin in the 1st/2nd shift rail and secure with a light coat of grease. Slide the 1st/2nd shift rail into the case, through the shift fork and shift gate. Hold the detent ball and spring down until the shaft rail passes.
    10.  
    11. Secure the 1st/2nd shift rail and gate with the roll pins.
    12.  

    New Process 445 4-Speed Assembly
    1. Install the countershaft front bearing in the case using a 1 3 / 8 in. (35mm) socket as a driver. Grease the needle bearings prior to installation. Hold the bearings in place with a socket of suitable size while seating the bearing retainer. Drive the retainer in until it is flush with the case.
    2.  
    3. Install the tanged thrust washer on the countershaft with the tangs facing out. Install the countershaft in the transmission case.
    4.  
    5. Install the countershaft rear bearing retainer over the rear bearing. Use a new washer and position the retainer with the curved segment toward the bottom of the case.
    6.  
    7. Install the reverse idler gear into the case with the chamfered section facing the rear. Hold the thrust washer and needle bearings in position.
    8.  
    9. Slide the reverse idler shaft into the case, from the rear, and through the reverse idler gear. Make sure that the lock notch is down and at the rear of the case.
    10.  
    11. Install the reverse idler shaft lock and bolt.
    12.  
    13. Place the mainshaft in a soft-jawed vise with the front end facing up.
    14.  
    15. Install the drive gear on top of the mainshaft.
    16.  
    17. Measure the clearance between the high-speed synchronizer and the drive gear with two feeler gauges. If the clearance is greater than 0.043-0.053 in. (1.0-1.3mm), install synchronizer shims between the 3rd gear and the synchronizer brake drum. After the required shims have been installed, remove the drive gear from the mainshaft.
    18.  
    19. Install the mainshaft into the transmission case. Place the thrust washer over the pilot end of the mainshaft.
    20.  
    21. Position the drive gear so that the cutaway portion of the gear is facing down. Slide the drive gear into the front of the case and engage the mainshaft pilot in the pocket of the drive gear.
    22.  
    23. Slip the drive gear front bearing retainer over the shaft on gasket, and do not secure with bolts.
    24.  
    25. Install the mainshaft rear bearing retainer. Tighten the screws to 11 ft. lbs. (27 Nm).
    26.  
    27. Hold the retainer against the front of the transmission case and measure the clearance between the front bearing retainer and the front of the case with a feeler gauge. Record the measurement and remove the bearing retainer.
    28.  
    29. Install a gasket pack on the front bearing retainer which is 0.010-0.015 in. (0.2-0.3mm) thicker than the clearance measured in Step 5. Install the front bearing retainer and torque attaching screws to 11 ft. lbs. (27 Nm).
    30.  
    31. The end-play float of the front synchronizer must be checked before installation of the transmission cover assembly. Measure the end-play by inserting two feeler gauges opposite one another between the 3rd gear and the synchronizer stop ring. Accurate measurement can be made only after all mainshaft parts are in place and torqued to specification.
    32.  
    33. If the front synchronizer end-play does not fall between 0.05-0.07 in. (1.2-1.7mm), shims should be added or removed as required, from between the 3rd gear and the synchronizer stop ring.
    34.  
    35. Install the yoke retaining nut on the rear of the mainshaft. Shift the transmission into two gears at the same time and torque the yoke nut to 31 ft. lbs. (169 Nm).
    36.  
    37. Shift the transmission into neutral.
    38.  
    39. Install the cover gasket.
    40.  
    41. Shift the transmission into 2nd gear. Shift the cover into 2nd.
    42.  
    43. Carefully lower the cover into position. It may be necessary to position the reverse gear to permit the fork to engage its groove.
    44.  
    45. Install the cover aligning screws (shouldered) and tighten with your fingers only.
    46.  
    47. Install the remaining cover screws, then tighten all the cover screws to 19 ft. lbs. (41 Nm).
    48.  

    New Process A-230 3-Speed Disassembly

    See Figure 12



    Click image to see an enlarged view

    Fig. Fig. 12: A-230 exploded view

    The A-230 is a three-speed transmission equipped with two synchronizer units to assist in the engagement of all forward gears. Lubricant capacity is approximately 5 pints.

    SHIFT HOUSING AND MECHANISM
    1. Shift to 2nd gear.
    2.  
    3. Remove side cover retaining bolts and lift the shift mechanism from the case.
    4.  
    5. If shaft O-ring seals need replacement, pull the shift-forks out of the shafts.
    6.  
    7. Remove nuts and operating levers from shafts.
    8.  
    9. Deburr shafts before removing to avoid scoring the bores.
    10.  
    11. Remove shafts by pushing through the housing bores.
    12.  
    13. Remove the O-ring retainers and O-rings from the housing.
    14.  

    DRIVE PINION RETAINER AND EXTENSION HOUSING
    1. Remove the pinion bearing retainer from the front of the transmission case. Pry off the retainer oil seal.
    2.  
    3. For clearance, use a brass drift to tap the drive pinion as far forward as possible. Rotate the cut-away part of the 2nd gear next to the countershaft gear. Shift the 2nd/3rd synchronizer sleeve forward.
    4.  
    5. Remove the speedometer pinion adapter retainer by removing the bolt securing it to the extension housing. Work the adapter and pinion out of the extension housing.
    6.  
    7. Unbolt the extension housing.
    8.  
    9. Break the housing loose with a plastic hammer and carefully remove it.
    10.  

    IDLER GEAR AND MAINSHAFT
    1. Insert a dummy shaft in the case to push the reverse idler shaft and key out of the case.
    2.  
    3. Remove the dummy shaft and idler rollers.
    4.  
    5. Remove both tanged idler gear thrust washers.
    6.  
    7. Remove the mainshaft assembly through the rear of case.
    8.  

    COUNTERSHAFT GEAR AND DRIVE PINION

    Remove the magnetic disc from the bottom of the case by prying off the retaining clip with a tool. Removal of the disc is necessary to gain the necessary clearance for dropping the countershaft gear.

    The cup and disc should be discarded for chip collection, and instead, the drain plug should be replaced with a magnetic plug assembly.

    1. Using a mallet and dummy shaft, tap the countershaft rearward enough to remove the key. Drive the countershaft out of the case, being careful not to drop the washers.
    2.  
    3. Lower the countershaft gear to the bottom of the case so you can remove the main drive pinion.
    4.  
    5. Remove the snapring from the pinion bearing outer race (outside the front of the case).
    6.  
    7. Drive the pinion shaft into the case with a plastic hammer. Remove the assembly through the rear of case.
    8.  
    9. If the bearing is to be replaced, remove the snapring and press off the bearing.
    10.  
    11. Lift the countershaft gear and dummy shaft out through the rear of the case.
    12.  

    New Process A-230 Component Disassembly
    MAINSHAFT

    See Figure 13

    1. Remove the snapring from the front end of the mainshaft along with the 2nd gear stop ring and 2nd gear.
    2.  
    3. Spread the snapring in the mainshaft bearing retainer. Slide the retainer back off the bearing race.
    4.  
    5. Remove the snapring at the rear of the mainshaft. Support the front side of the reverse gear. Press the bearing off the mainshaft.
    6.  
    7. Remove the mainshaft from the press. Remove the mainshaft bearing and reverse gear from the shaft.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 13: Mainshaft assembled with gears and rings

    1. Remove the snapring and 1st/reverse synchronizer assembly from the shaft. Remove the stop ring and 1st gear rearward.
    2.  

    New Process A-230 Assembly
    COUNTERSHAFT GEAR
    1. Slide a dummy shaft into the countershaft gear.
    2.  
    3. Slide one roller thrust washer over the dummy shaft and into the gear, followed by 14 greased rollers.
    4.  
    5. Repeat Step 2, adding one roller thrust washer on the end.
    6.  
    7. Repeat Steps 2 and 3 at the other end of the countershaft gear. There is a total of 88 rollers and 6 thrust washers.
    8.  
    9. Place the greased front thrust washer on the dummy shaft against the gear with the tangs forward.
    10.  
    11. Grease the rear thrust washer and stick it in place in the case, with the tangs rearward.
    12.  
    13. Place the countershaft gear assembly in the bottom of the transmission case until the drive pinion is installed.
    14.  

    Do not finish installation with the countershaft and key until the drive pinion is installed.

    PINION GEAR

    See Figure 14

    1. Press the new bearing on the pinion shaft with the snapring groove forward. Install a new snapring.
    2.  
    3. Install 7 rollers and the retaining ring in the drive pinion gear.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 14: Installing the rollers in the drive pinion

    1. Install the drive pinion and bearing assembly into the case.
    2.  
    3. Position the countershaft gear assembly by placing it and the thrust washers so the countershaft can be tapped into position. Be careful to keep the countershaft against the dummy shaft to keep the parts from falling between them.
    4.  
    5. Install the key in the countershaft.
    6.  
    7. Tap the drive pinion forward for clearance.
    8.  

    MAINSHAFT
    1. Place a stop ring flat on the bench. Place a clutch gear and a sleeve on top. Drop the struts in their slots and insert a strut spring with the tang inside on strut. Turn the assembly over and install the 2nd strut spring, tang in a different strut.
    2.  
    3. Slide the 1st gear and stop ring over rear of the mainshaft and against the thrust flange. Slide the 1st and second gears on the shaft.
    4.  
    5. Slide on the 1st/reverse synchronizer, indexing the hub slots with the 1st gear stop ring lugs.
    6.  
    7. Install the 1st/reverse synchronizer clutch gear snapring on the mainshaft.
    8.  
    9. Slide the reverse gear and mainshaft bearing on the shaft, supporting the inner race of the bearing. Be sure the snapring groove on the outer race is forward.
    10.  
    11. Install the bearing retaining snapring on mainshaft. Slide the snapring over the bearing and seat it in the groove.
    12.  
    13. Place 2nd gear over the front of the mainshaft with the thrust surface against the flange.
    14.  
    15. Install the stop ring and the 2nd/3rd synchronizer assembly against 2nd gear. Install the 2nd/3rd synchronizer clutch gear snapring on the shaft.
    16.  
    17. Move the 2nd/3rd synchronizer sleeve forward as far as possible. Install the front stop ring inside the sleeve with the lugs indexed with the struts.
    18.  
    19. Rotate the cut out on the 2nd gear toward the countershaft gear for clearance.
    20.  
    21. Insert the mainshaft assembly into the case. Tilt the assembly to clear the cluster gears and insert the pilot rollers in the drive pinion gear. If the assembly is correct, the bearing retainer will bottom in the case without force. If not, check for a misplaced strut, pinion roller, or stop ring.
    22.  

    REVERSE IDLER GEAR
    1. Place a dummy shaft into the idler gear. Insert 14 greased rollers.
    2.  
    3. Position the reverse idler thrust washers in the case with grease.
    4.  
    5. Position the idler gear and dummy shaft in the case.
    6.  
    7. Install the idler shaft and key.
    8.  

    EXTENSION HOUSING BUSHING
    1. Remove the extension housing yoke seal.
    2.  
    3. Drive the bushing out from inside the housing.
    4.  
    5. Align the oil hole in the bushing with the oil slot in the housing. Drive the bushing into place.
    6.  
    7. Drive a new seal into the housing.
    8.  
    9. Install the extension housing and gasket to hold the mainshaft and bearing retainer in place.
    10.  

    DRIVE PINION BEARING RETAINER
    1. Install the outer snapring on the drive pinion bearing. Tap the assembly back until the snapring contacts the case.
    2.  
    3. Using a seal installer tool or equivalent, install a new seal in the retainer bore.
    4.  
    5. Position the main drive pinion bearing retainer and gasket on the front of the case. Coat the threads with sealing compound, install the bolts and torque them to 19 ft. lbs. (41 Nm).
    6.  

    GEARSHAFT MECHANISM AND HOUSING
    1. If removed, place the two interlock levers in the pivot pin with the spring hangers offset toward each other, so that the spring installs in a straight line. Place the E-clip on the pivot pin.
    2.  
    3. Grease and install new O-ring seals on both shift shafts. Grease the housing bores and insert the shafts.
    4.  
    5. Install the spring on the interlock lever hangers.
    6.  
    7. Rotate each shift shaft fork bore to the straight up position. Install the shift forks through the bores and under both interlock levers.
    8.  
    9. Position the 2nd/3rd synchronizer sleeve to the rear, in the 2nd gear position. Position the 1st/reverse synchronizer sleeve to the middle of its travel, in the neutral position. Place the shift forks in the same positions.
    10.  
    11. Install the gasket and gearshift mechanism. The bolt with the extra long shoulder must be installed at the center rear of the case. Torque the bolts to 7 ft. lbs. (20 Nm).
    12.  
    13. Install the speedometer drive pinion gear and adapter. The range number on the adapter, which represents the number of teeth on the gear, should be in the 6 o'clock position.
    14.  

    New Process A-250 3-Speed Disassembly

    See Figures 15 and 16

    The A-250 is a 3-speed transmission equipped with a synchronizer between 2nd and 3rd gears. Lubricant capacity is approximately 4 1 / 2 pints.

    1. Remove the case cover and gasket.
    2.  
    3. Measure the synchronizer "float'' with a pair of feeler gauges. Measurement is made between the synchronizer outer ring pin and the opposite synchronizer outer ring. This measurement must be made on two pins 50° apart with equal gap on both ends for float determination. The measurement should be 0.060-0.117 in. (1.5-2.9mm). A snug fit should be maintained between the feeler gauge and the pins.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 15: Exploded view of the A-250 transmission

    1. Remove the bolt and retainer holding the speedometer pinion adapter in the extension housing. Carefully work the adapter and pinion out of the extension housing.
    2.  
    3. Remove the extension housing bolts and the extension housing.
    4.  
    5. Remove the bolts that attach the drive pinion bearing retainer to the case, then slide the retainer off the pinion. Pry the seal out of retainer using a screwdriver. Be careful not to nick or scratch the bore.
    6.  
    7. Rotate the drive pinion so that the blank clutch tooth area is opposite the countershaft for removal clearance.
    8.  
    9. Slide the drive pinion assembly slightly out of the case. Move the synchronizer front inner stop ring from the short splines on the pinion shaft. Slowly remove the drive pinion assembly.
    10.  
    11. Remove the snapring that holds the bearing on the pinion shaft. Remove the pinion bearing washer. Press the pinion shaft out of the bearing using an arbor press. Remove the oil slinger.
    12.  
    13. Remove the snapring and bearing rollers from the end of the drive pinion.
    14.  
    15. Remove the clutch gear retaining snapring from the mainshaft.
    16.  
    17. Remove the mainshaft bearing securing snapring from the case.
    18.  
    19. Slide the mainshaft and bearing rearward out of the case while holding the gears as they drop free.
    20.  
    21. Remove the snapring from the mainshaft and press the bearing off of the mainshaft.
    22.  
    23. Remove the synchronizer components, 2nd gear, 1st/reverse gear and shift forks from case.
    24.  



    Click image to see an enlarged view

    Fig. Fig. 16: Exploded view of the synchronizer assembly on the A-250

    Steps 7 through 6 need only be performed if gear shift lever seals are leaking.

    1. Remove the shift levers from the shift shafts.
    2.  
    3. Drive out the tapered retaining pin from the 1st/reverse shift shaft. Remove the shift shaft from inside the case. As the detent balls are spring loaded, when the shafts are removed the balls will drop to the bottom of the transmission case.
    4.  
    5. Remove the interlock sleeve, spring and both detent balls from the case. Drive the tapered retaining pin out of the 2nd/3rd shaft and remove the shaft from the case.
    6.  
    7. Drive the shift shaft seals out of the case with a suitable drift.
    8.  
    9. Check the end-play of countershaft gear with a feeler gauge. The end-play should be between 0.005-0.022 in. (0.10-0.55mm). This measurement is used to determine if a new thrust washer is necessary during reassembly.
    10.  
    11. Using a countershaft bearing arbor, drive the countershaft towards the rear of the case until the small key can be removed from the countershaft.
    12.  
    13. Drive the countershaft the rest of the way out of the case, keeping the arbor tight against the end of the countershaft. This will prevent loss of the roller bearings.
    14.  
    15. Remove the countershaft gear, front thrust washer and rear thrust washer from the case.
    16.  
    17. Remove the bearing rollers, spacer ring and center spacer from the countershaft gear.
    18.  
    19. Drive the reverse idler gear shaft out of the transmission case using a suitable drift. Remove the Woodruff key from the end of the reverse idler shaft.
    20.  
    21. Remove the reverse idler gear and thrust washers out of the case. Remove the bearing rollers from the gear.
    22.  

    New Process A-250 3-Speed Assembly
    1. Slide the countershaft gear bearing roller spacer over arbor tool. Coat the bore of gear with lubricant and slide tool and spacer into gear bore.
    2.  
    3. Lubricate the bearing rollers with heavy grease and install two rows of 14 rollers each in both ends of the gear in area around arbor. Cover with heavy grease and install the bearing spacer rings in each end of the gear and between the roller rows.
    4.  
    5. If the countershaft gear end-play was found to be excessive during disassembly, install new thrust washers. Cover with heavy grease and install the thrust washer and thrust needle bearing and cap at each end of the countershaft gear and over the arbor. Install the gear and arbor in the case, and make sure that the tabs on the rear thrust washer slide into the grooves in the case.
    6.  
    7. Drive the arbor forward out of the countershaft gear and through the bore in the front of the case using the countershaft and a soft faced hammer. When the countershaft is almost in place, make certain the keyway in the countershaft is aligned with the key slot in the rear of the case. Insert the shaft key and continue to drive the countershaft into the case until the key is bottomed in the slot.
    8.  
    9. Position the special arbor tool in the reverse idler gear and install the 14 roller bearings using a heavy grease.
    10.  
    11. Place the front and rear thrust washers at each end of the reverse idler gear. Position the assembly in the transmission case with the chamfered end of the gear teeth towards the front. Make sure that the thrust washer tabs engage the slots in the case.
    12.  
    13. Insert the reverse idler shaft into the bore at rear of case with the keyway to the rear, pushing the arbor towards the front of the case.
    14.  
    15. When the keyway is aligned with the slot in the case, insert the key in the keyway. Drive the shaft forward until the key is seated in the recess.
    16.  

    Steps 9 through 5 need only be performed if the shift levers have been disassembled.

    1. Place new shift shaft seals in the case and drive them into position with a suitable drift.
    2.  
    3. Carefully slide the 1st/reverse shift shaft into the case and lock it into place with a tapered retaining pin. Position the lever so that the center detent is aligned with the interlock bore.
    4.  
    5. Install the interlock sleeve into the bore followed by a detent ball, spring and pin.
    6.  
    7. Install the remaining detent ball and hold it in place with a detent ball holding tool.
    8.  
    9. Depress the detent ball and carefully install the 2nd/3rd shift shaft. Align the center detent with the detent ball and secure the lever with the tapered retaining pin.
    10.  
    11. Install the shift levers and tighten the retaining nuts to 6 ft. lbs. (24 Nm).
    12.  
    13. Press the bearing on the mainshaft and select and install a snapring that gives minimum end-play.
    14.  
    15. Move the shift lever to the reverse position, and then place the 1st/reverse gear and shift fork in the case.
    16.  

    Both shift forks are offset toward the rear of the transmission case.

    1. Assemble the synchronizer parts with the shift fork and 2nd gear.
    2.  
    3. Place the 2nd gear assembly in the transmission case and insert the shift fork into its lever.
    4.  
    5. Install the mainshaft carefully through the gear assembly until it bottoms in rear of case.
    6.  
    7. Install the synchronizer clutch gear snapring on the mainshaft.
    8.  
    9. Select and install the mainshaft bearing snapring in the case.
    10.  
    11. If the float measurement was found to be above or below 0.117 in. (2.9mm), install or remove shims to place the float within range.
    12.  
    13. Install the oil slinger on the drive pinion shaft and slide it against the gear.
    14.  
    15. Slide the bearing over the pinion shaft with the snapring groove away from the gear, then seat the bearing on the shaft using an arbor press.
    16.  
    17. Install the keyed washer between the bearing and the retaining snapring groove.
    18.  
    19. Secure the bearing and washer with the selected thickness snapring. If the large snapring around bearing was removed, install it at this time.
    20.  
    21. Place the drive pinion shaft in a vise with soft faced jaws and install the 5 roller bearings in the shaft cavity. Coat the roller bearings with a heavy grease and install the retaining ring in the groove.
    22.  
    23. Rotate the drive pinion so that the blank clutch tooth area is next to the countershaft. Guide the drive pinion through the front of case and engage the inner stop ring with the clutch teeth. Then seat the pinion bearing. The pinion shaft is fully seated when the snapring is in full contact with the case.
    24.  
    25. Install a new seal in the pinion bearing retainer.
    26.  
    27. Position the retainer assembly and new gasket on the case. Use sealing compound on the bolts and tighten to 19 ft. lbs.
    28.  
    29. Slide the extension housing and a new gasket over the mainshaft. Guide the shaft through the bushing and oil seal. Use sealing compound on the bolt used in the hole tapped through the transmission case. Install the remaining bolts and tighten them all to 36 ft. lbs. (67 Nm).
    30.  
    31. Install the transmission cover and gasket, then tighten the cover bolts to 4 ft. lbs. (16 Nm).
    32.  
    33. Rotate the speedometer pinion gear and adapter assembly so that the number on the adapter corresponding to the number of teeth on the gear is in the 6 o'clock position as the assembly is installed.
    34.  
    35. Fill the transmission with the proper lubricant and install the drain plug, then tighten to 15 ft. lbs. (33 Nm). Install the back-up light switch and tighten to 7 ft. lbs. (20 Nm).
    36.  
    37. Rotate the drive pinion shaft and check the operation of the transmission by running the transmission through all the gear ranges.
    38.  

    New Process A-390 Disassembly

    The A-390 is a three speed synchromesh transmission. Lubricant capacity is approximately 4 1 / 2 pints.

    EXTENSION HOUSING

    See Figures 17 and 18

    1. Remove the bolts that attach the cover to the case. Remove the cover and gasket.
    2.  
    3. Remove the long spring that retains the detent plug in the case. Remove the detent plug with a small magnet.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 17: A-390 Right side view



    Click image to see an enlarged view

    Fig. Fig. 18: A-390 Left side view

    1. Remove the bolt and retainer securing the speedometer pinion adapter to the transmission case. Carefully work the adapter and pinion out of the extension housing.
    2.  
    3. Remove the bolts that attach the extension housing to the transmission case. Slide the extension housing off the output shaft.
    4.  

    INPUT SHAFT BEARING RETAINER
    1. Remove the bolts that attach the input shaft bearing retainer to the case. Slide the retainer off the shaft. Using a suitable tool, pry the seal out of the retainer. Be careful not to nick or scratch the bore in which the seal is pressed or the surface on which the seal is bottomed.
    2.  

    OUTPUT SHAFT, INPUT SHAFT AND SHIFT FORKS

    See Figures 19, 20 and 21

    1. Remove the lubricant fill plug from the right side of the case. Working through the fill plug opening, drive the roll pin out of the countershaft with a 1 / 4 in. (6mm) punch.
    2.  
    3. Working with the countershaft bearing arbor and a soft faced hammer, tap the countershaft toward the front of the case with the arbor tool to remove the expansion plug from the countershaft bore at the front of the case. The countershaft is a loose fit in the case and will slide easier.
    4.  
    5. Insert the arbor tool through the front of the case and push the countershaft out of the rear of the case so the roll pin hole in the countershaft does not travel through the roller bearings. The countershaft gear will drop to the bottom of the case. Remove the countershaft from the rear of the case.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 19: Exploded view of the A-390

    1. Place both shift levers in neutral (center) position.
    2.  
    3. Remove the input shaft assembly and stop ring from the front of the case.
    4.  
    5. Remove the set screw that secures the 1st/reverse shift fork to the shift rail. Slide the 1st/reverse shift rail out through the rear of the case.
    6.  
    7. Move the 2nd/3rd shift fork rearward for access to the set screw. Remove the set screw from the fork. Using a suitable tool, rotate the shift rail one quarter ( 1 / 4 ) turn.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 20: Rotating 2nd-3rd shift rail 1/4 turn

    1. Lift the interlock plug from the case with a magnet.
    2.  
    3. Tap on the inner end of the 2nd/3rd shift rail to remove the expansion plug from the front of the case. Remove the shift rail through the front of the case.
    4.  
    5. Remove the 2nd/3rd shift rail detent plug and spring from the detent bore with a magnet.
    6.  
    7. Tap the output shaft assembly rearward until the output shaft bearing clears the case. Remove both shift forks. Remove the snapring that retains the output shaft bearing to the output shaft.
    8.  
    9. Assemble the output shaft bearing removal tool over the output shaft and bearing. Remove the output shaft bearing.
    10.  
    11. Remove the output shaft assembly through top of the case.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 21: Removing and installing the output shaft assembly

    REVERSE IDLER GEAR

    See Figure 22

    1. Using a suitable drift, drive the reverse idler gear shaft toward the rear, and out of the transmission case.
    2.  
    3. Lift the reverse idler gear and thrust washer out of the case.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 22: Disassembled reverse idler gear

    COUNTERSHAFT GEAR

    See Figure 23

    1. Remove the countershaft gear, arbor assembly, and thrust washers from the bottom of the case.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 23: Remove the counter shaft from the housing

    1. Remove the countershaft roll pin from the bottom of the case.
    2.  

    OUTPUT SHAFT

    See Figure 24

    1. Remove the snapring that retains the 2nd/3rd synchronizer clutch gear and sleeve assembly on the output shaft. Slide the 2nd/3rd synchronizer assembly off the end of the output shaft.
    2.  

    Do not separate the 2nd/3rd synchronizer clutch gear, sleeve, struts, or spring unless inspection reveals that a replacement is necessary.

    1. Slide the 2nd gear and stop ring off the output shaft.
    2.  
    3. Remove the snapring and thrust washer retaining the 1st gear. Slide the 1st gear and stop ring off the output shaft.
    4.  
    5. Remove the snapring that retains the 1st/reverse synchronizer hub on the output shaft. The 1st/reverse synchronizer hub is a press fit on the output shaft. To avoid damage to the synchronizer, remove the synchronizer hub using an arbor press. Do not attempt to remove or install the hub by hammering or prying.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 24: Installing and removing the 1st-Reverse synchronizer hub

    New Process A-390 Parts Replacement
    SHIFT LEVERS and SEALS
    1. Remove the operating levers from their respective shafts. Remove any burrs from the shafts to avoid damage to the case.
    2.  
    3. Push the shift levers out of the transmission case. Remove and discard the O-ring seal from each shaft.
    4.  
    5. Lubricate the new seals with transmission oil and install them on the shafts.
    6.  
    7. Install the shift levers in the case.
    8.  
    9. Install the operating levers and tighten the retaining nuts to 6 ft. lbs. (24 Nm).
    10.  

    INPUT SHAFT BEARING AND ROLLERS

    See Figure 25

    1. Remove the snapring securing the bearing on the input shaft. Carefully press the input shaft out of the bearing with an arbor press.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 25: Using an arbor press to remove the input shaft bearing

    1. Remove the fifteen bearing rollers from the cavity in the end of the input shaft.
    2.  
    3. Install the 7 bearing rollers in the cavity of the input shaft. Coat the rollers with a thin film of grease to retain them during installation.
    4.  
    5. Slide the input shaft bearing over the input shaft, snapring groove away from the gear end. Seat the bearing assembly on the input shaft with an arbor press.
    6.  
    7. Secure the bearing with the snapring. Be sure the snapring is properly seated. If a large snapring around the bearing was removed, be sure to install it at this time.
    8.  

    SYNCHRONIZERS

    See Figures 26 and 27

    If either synchronizer is to be disassembled, mark all parts so that they will be reassembled in the same position. Do not mix parts from the two synchronizers.

    1. Push the synchronizer hub off each synchronizer sleeve.
    2.  
    3. Separate the struts and springs from the hubs.
    4.  
    5. Install the spring on the front side of the 1st/reverse synchronizer hub, making sure that all three strut slots are fully covered. Hang the three struts on the spring and in the slots with the wide end of the strut inside the hub.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 26: Assembly of the 1st-Reverse synchronizer

    1. With the alignment marks on the hub and sleeve aligned, push the sleeve down on the hub until the struts are in the neutral detent. Place the stop ring on top of the synchronizer assembly.
    2.  
    3. With the alignment marks on the 2nd/3rd synchronizer sleeve and hub aligned, slide the sleeve on the hub. Drop in the three struts in the strut slots. Install the spring with the hump in the center, into the hollow of the strut. Turn the assembly over and install the other spring so that the hump in the center of the spring is inserted in the same strut. Place the stop ring on each end of the synchronizer assembly.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 27: Rebuilding the 2nd-3rd synchronizer

    COUNTERSHAFT GEAR AND BEARINGS
    1. Remove the countershaft bearing arbor, the roller bearings and the two bearing retainers from the countershaft gear.
    2.  
    3. Coat the bore in each end of the countershaft gear with grease.
    4.  
    5. Insert the countershaft arbor and install twenty five roller bearings and the retainer washer in each end of the countershaft gear.
    6.  
    7. Position the countershaft gear and arbor assembly in the transmission case. Align the gear bore and the thrust washers with the bores in the case and install the countershaft.
    8.  
    9. Using a feeler gauge, check the countershaft gear end-play. The end-play should be within 0.004-0.018 in. (0.10-0.40mm). If the clearance is not within limits, replace the thrust washers.
    10.  
    11. After establishing the correct end-play, install the arbor tool in the countershaft gear and lower the gear and tool out of the bottom of the transmission case.
    12.  

    New Process A-390 Assembly
    OUTPUT SHAFT
    1. Coat the countershaft gear thrust surfaces in the case with a thin film of grease and position the two thrust washers. Place the countershaft gear and arbor assembly in the proper position in the bottom of the transmission case. The countershaft gear will remain in the bottom of the case until the output and input shafts are installed.
    2.  
    3. Coat the reverse idler gear thrust surfaces in the case with a thin film of grease and position the two thrust washers. Install the reverse idler gear in the case and align the gear bore with the thrust washers in the case bore. Install the reverse idler shaft.
    4.  
    5. Measure the reverse idler gear end-play with a feeler gauge. End-play should be 0.004-0.018 in. (0.10-0.40mm). If the clearance is not within limits, replace the thrust washers. If the end-play is correct, leave the reverse idler gear in place.
    6.  
    7. Lubricate the output shaft splines and the machined surfaces with transmission oil.
    8.  
    9. Slide the 1st/reverse synchronizer onto the output shaft with the fork groove toward the front. The 1st/reverse synchronizer hub is a press fit on the output shaft. To eliminate the possibility of damage to the hub, install the hub using an arbor press.
    10.  

    Do not attempt to install the hub by hammering or driving.

    1. Secure the hub on the output shaft with the snapring. Slide the 1st gear and stop ring onto the output shaft, aligning the slots in the stop ring with the struts. Install the thrust washer and snapring.
    2.  
    3. Slide the 2nd gear and stop ring on the output shaft.
    4.  
    5. Install the 2nd/3rd synchronizer assembly on the output shaft. Rotate the 2nd gear to index the struts with the slots in the stop ring. Secure the synchronizer with a snapring.
    6.  
    7. Position the output shaft assembly in the transmission case. Place the transmission in a vertical position with the front of the case flat on the work bench. Place a 1 1 / 4 in. (31mm) block of wood under the end of the output shaft. The block of wood will hold the output shaft assembly up during installation of the output shaft bearing.
    8.  
    9. Install the large snapring on the output shaft bearing. Place the bearing on the output shaft with the large snapring up. Drive the bearing on the shaft until it is seated on the shaft. Secure the bearing on the output shaft with the snapring. Return the transmission to a horizontal position.
    10.  
    11. Insert both shift forks in the case and in their proper sleeves. Push the output shaft assembly into position and tap it forward until the output shaft bearing is seated in the transmission case.
    12.  
    13. Install the shortest detent spring followed by a detent plug into the case. Place the 2nd/3rd synchronizer assembly in the 2nd gear position.
    14.  
    15. Align the 2nd/3rd shift fork and install the 2nd/3rd shift rail. The 2nd/3rd shift rail is the shortest of the two shift rails. It will be necessary to depress the detent plug to enter the shift rail in the bore. Move the rail inward until the detent plug engages the forward notch (2nd gear position).
    16.  
    17. Secure the fork to the rail with the setscrew. Move the synchronizer to the neutral position.
    18.  
    19. Install a new expansion plug in the transmission case.
    20.  
    21. Install the interlock plug in the transmission case with a magnet. If the 2nd/3rd shift rail is in the neutral position, the top of the interlock plug will be slightly lower than the surface of the 1st/reverse shift rail bore.
    22.  
    23. Align the 1st/reverse fork and install the 1st/reverse shift rail. Move the rail inward until the center notch (neutral) is aligned with the detent bore. Secure the fork to the rail with the set screw.
    24.  

    INPUT SHAFT AND RETAINER SEAL
    1. Using a suitable tool, install a new oil seal in the input shaft bearing retainer bore.
    2.  
    3. Coat the bore of the input shaft gear with a thin film of grease.
    4.  

    A thick, heavy grease will plug the lubricant holes and prevent lubrication of the roller bearings.

    1. Install the fifteen roller bearings in the bore. Place the stop ring, slots aligned with the struts, into the 2nd/3rd synchronizer. Tap the input shaft assembly into place in the case while holding the output shaft to prevent the roller bearings from dropping.
    2.  

    COUNTERSHAFT GEAR
    1. Roll the transmission over so that it rests on both the top edge and the shift levers. The countershaft gear will drop into place. Using a screwdriver, align the countershaft gear and thrust washers with the bore in the transmission case.
    2.  
    3. Working from the rear of the case, slide the countershaft into position being careful to keep the countershaft in contact with the arbor to avoid dropping parts out of position. Be sure that the roll pin hole in the countershaft aligns with the roll pin hole in the case.
    4.  
    5. Install the roll pin. Install a new expansion plug in the countershaft bore at the front of the case. Install the plug flush or below the face of the case to prevent interference with the clutch housing.
    6.  

    EXTENSION HOUSING AND INPUT SHAFT BEARING RETAINER
    1. Slide the extension housing, with a new gasket, over the output shaft and against the case. Coat the attaching bolt threads with a sealing compound. Install and tighten the attaching bolts to 36 ft. lbs. (67 Nm).
    2.  
    3. Install the input shaft bearing retainer and a new gasket. Make sure that the oil return slot is at the bottom. Coat the threads with a sealing compound, install the attaching bolts and tighten to 19 ft. lbs. (40 Nm).
    4.  

    COVER
    1. Install the remaining detent plug into the case followed by the detent spring.
    2.  
    3. Install the filler plug and the back-up light switch. Pour lubricant over the entire gear train while rotating the input shaft and the output shaft.
    4.  
    5. Place the cover and a new gasket on the transmission. Coat the attaching screw threads with a sealing compound. Install and tighten the attaching screws to 14 ft. lbs. (29 Nm).
    6.  

    New Process 420 4-Speed Disassembly

    The four speed Model 420 Transmission is a strong, exceptionally smooth, easy shifting transmission. All gears are of helical design except 1st and reverse which are spur type. The countershaft and all its gears are a single unit. Engagement of the 3rd and 4th gear is aided by pin type synchronizers.

    Lubricant capacity is approximately 5 1 / 2 pints. Power take-off outputs are located on both sides of the case.

    1. Shift the gears into neutral.
    2.  
    3. Remove the cover by turning it slightly counterclockwise.
    4.  
    5. Check and record the amount of synchronizer end-play for assembly reference.
    6.  
    7. Remove the yoke and parking brake drum as an assembly.
    8.  

    The drum and yoke are balanced and, unless replacement of a part is required, it is recommended that the drum and yoke be removed as a unit.

    1. Remove the speedometer drive pinion and the rear mainshaft bearing support.
    2.  

    MAIN DRIVE GEAR
    1. Remove the main drive gear bearing retainer.
    2.  
    3. Move the synchronizer towards the rear and, while slowly rotating the main drive gear, tap on the main drive gear shaft with a soft hammer and pull at the same time. A few of the clutch teeth on the main drive are missing to facilitate its removal past the cluster gears. This open space must be positioned at the bottom to allow withdrawal of the main drive gear from the transmission case.
    4.  

    MAINSHAFT
    1. Using a brass drift, drive the mainshaft to the rear making certain that the synchronizer assembly remains free on the shaft.
    2.  
    3. Using a puller, remove the rear bearing and speedometer gear (with spacer).
    4.  
    5. Remove the sliding components of the synchronizer separately.
    6.  
    7. Remove the mainshaft assembly.
    8.  

    REVERSE IDLER GEAR

    Remove the reverse idler lockscrew and lockplate and lift the idler shaft from the gear case.

    COUNTERSHAFT CLUSTER GEAR
    1. Remove the bearing retainers at opposite ends of the countershaft. Make sure the roller bearing assembly at the rear end of shaft remains with the retainer.
    2.  
    3. Remove the cluster gear assembly from the case.
    4.  
    5. Remove the front bearing.
    6.  

    New Process 420 Component Disassembly
    MAINSHAFT
    1. Remove the clutch gear snapring.
    2.  
    3. Remove the clutch gear, synchronizer outer stop ring-to-3rd speed gear shim (or shims) and the 3rd speed gear.
    4.  
    5. Remove the split lockring and remove the 2nd speed gear.
    6.  
    7. Remove the 1st/2nd sliding gear.
    8.  
    9. Drive the old seal from the rear bearing support housing.
    10.  

    COUNTERSHAFT

    The cluster gears are integral with the shaft. The rear bearing and retainer are unserviceable items. They must be replaced if worn.

    REVERSE IDLER

    If necessary, press in a new bushing.

    COVER AND SHIFT FORK
    1. Remove the roll pin from the 3rd/4th shift fork (center rail) with a screw extractor.
    2.  

    A square type or a closely wound spiral screw extractor mounted in a tap handle is preferable for this operation.

    1. After removing the pin, drive the rail to the rear and remove the fork.
    2.  
    3. Continue driving the rail to rear to remove the rear expansion plug, being careful to catch the detent ball and spring. Also, note the interlock pin and rail.
    4.  
    5. Remove the remaining rails, lugs and shift forks in the same manner as the center rail.
    6.  

    It is very seldom that the interlocks require removal from cover. However, to replace the interlocks, remove the plug from the interlock passage in the cover.

    1. Remove the reverse spring loaded plunger from the lug (if required) by removing the horse shoe lock from the plunger shaft.
    2.  

    MAIN DRIVE PINION
    1. Secure the main drive pinion gear in a soft jawed vise and remove the bearing retaining locknut.
    2.  

    The retaining nut has left hand threads.

    1. Press the bearing from the shaft.
    2.  
    3. Remove the lockring, washer and pilot rollers from the gear.
    4.  

    New Process 420 Component Assembly

    When assembling, use new expansion plugs, gaskets and seals. Lubricate all parts with transmission lubricant before assembly.

    MAINSHAFT
    1. Place the mainshaft in a soft jawed vise with the forward end up.
    2.  
    3. Install the 2nd speed gear and lock in position with the split lockring.
    4.  
    5. Install the 3rd speed gear with the clutching teeth up.
    6.  
    7. Install the spacer shim (or shims) and clutch gear (oil slots down).
    8.  
    9. Install the clutch gear snapring, selecting the correct size to eliminate all clutch gear end-play. Snaprings are available in four thicknesses marked A, B, C and D. When installing the synchronizer assembly on the mainshaft, the selection of the 3rd speed gear shims will depend upon the number of shims originally used and the amount of end-play clearance recorded before disassembly. The number of shims necessary for correct end-play clearance 0.05-0.07 in. (1.2-1.7mm), cannot be accurately measured until all the mainshaft components are in position and properly tightened.
    10.  

    MAIN DRIVE PINION
    1. Press the bearing onto the main dive gear pinion seating it against the pinion shoulder.
    2.  
    3. Install the retainer nut (left hand thread) and tighten it securely.
    4.  
    5. Install the large snapring on the bearing race.
    6.  
    7. Lubricate the roller bearings to hold the rollers in place and insert them in the pocket of the main drive gear.
    8.  
    9. Install the washer and snapring.
    10.  

    COVER
    1. Sight along the reverse rail bore in the cover to be certain the interlock pin is clear of the hole. Enter the reverse rail into the bore at the rear of the cover. Push it in further and install the fork. Continue to push the rail into the cover until the rail enters the rail support containing the cavity for the detent ball and spring.
    2.  
    3. Install the spring and ball in the support, compress the spring, and push the rail over the ball.
    4.  
    5. Install the lug on the rail and install the plug in the cover.
    6.  
    7. Drive the roll pins through the lug, shift fork and rail.
    8.  
    9. Install the 1st/2nd shift rail assembly in the same manner followed by the 3rd/4th shift rail assembly, being certain that the interlock pin is in position in the 3rd/4th shift rail.
    10.  

    New Process 420 Installing Sub-Assemblies Into Case
    COUNTERSHAFT
    1. Lower the countershaft assembly into the case.
    2.  
    3. Install the front bearing and the front bearing washer, capscrews and lockwire and torque them to 15-30 ft. lbs. (33-40 Nm).
    4.  
    5. While holding the gear assembly in alignment, install the rear bearing support gasket and bearing assembly over the front bearing opening in the case. Install the end cover and gasket.
    6.  

    REVERSE IDLER
    1. Position the reverse gear in the case.
    2.  
    3. Align the groove in the idler shaft with the lockplate.
    4.  
    5. Tap the shaft into the case far enough to start the reverse gear.
    6.  
    7. While holding the gear in position, tap the shaft through the case and gear.
    8.  
    9. Install the lockplate, washer and cap screw.
    10.  
    11. Make sure the gear turns freely on the shaft.
    12.  

    MAINSHAFT AND MAIN DRIVE PINION
    1. Install the mainshaft and 1st speed gear through the rear bearing opening in the case.
    2.  
    3. With the shaft assembly moved to the rear of the case, install the synchronizer components one at a time.
    4.  
    5. Install the main drive pinion by tapping on the outer bearing race while guiding the mainshaft pilot into the roller bearing.
    6.  
    7. Make sure the bearing snapring is flush against the case.
    8.  
    9. Carefully drive the rear bearing onto the mainshaft and into the case (snapring flush against case) using a suitable sleeve against the inner race of the bearing.
    10.  
    11. Install the spacer and the speedometer gear.
    12.  
    13. Install the rear support and gasket.
    14.  
    15. Place the front main drive pinion bearing retainer over the pinion shaft without the gasket.
    16.  
    17. Hold the retainer tight against the bearing and measure the clearance between the retainer and case with a feeler gauge.
    18.  
    19. Select a gasket approximately 0.005 in. (0.12mm) thicker than the measured clearance and install the gasket and retainer.
    20.  
    21. End-play should be 0.003-0.006 in. (0.07-0.15mm).
    22.  
    23. Check the synchronizer end-play clearance 0.05-0.07 in. (1.2-1.7mm), after all mainshaft components are in position and properly tightened. If two sets of feeler gauges are used to measure this clearance, care should be used to keep the gauges as close as possible to both sides of the mainshaft for best results. In some cases, it may be necessary to change the thickness of the shims to keep the end-play clearance within the specified 0.05-0.07 in. (1.2-1.7mm).
    24.  
    25. Install the speedometer drive pinion.
    26.  
    27. Install the yoke flange, drum and brake assembly.
    28.  
    29. Final tightening of the nut may be made on the truck, however, lock the transmission to hold the shaft for preliminary tightening.
    30.  
    31. Shift the gears and/or synchronizer into all speed positions and check for free rotation. Be sure the synchronizer pins are properly aligned.
    32.  

    COVER
    1. Move the gears into the neutral position.
    2.  
    3. Carefully engage the forks into the proper gears and lower the cover and a new gasket into place.
    4.  
    5. Install one screw on each side of case and try the gears for free rotation by shifting the gears through the cover tower with a long screwdriver and then install the remaining screws.
    6.  
    7. Install the transmission in the truck and tighten the yoke flange retaining nut before connecting the universal joint.
    8.  
    9. Install the gear shift lever and check for proper shifting operation.
    10.  

    New Process A-745 3-Speed Disassembly

    See Figures 28 and 29



    Click image to see an enlarged view

    Fig. Fig. 28: NP745 exploded view with sliding spline

    The Dodge A-745 is a 3-speed synchromesh transmission having helical type gears. Lubricant capacity is approximately 3 1 / 4 pints.



    Click image to see an enlarged view

    Fig. Fig. 29: Exploded view of the NP745 for D100/W100 and D200/W200

    1. Remove the output flange nut, then the drum and flange assembly, if so equipped. Remove the parking brake assembly, if so equipped.
    2.  
    3. Remove the case cover. Measure the synchronizer float with a feeler gauge between the end of a synchronizer pin and the opposite synchronizer outer ring. A measurement from 0.05-0.09 in. (1.2-2.2mm) is acceptable for 867 models. The measurement should be 0.060-0.117 in. (1.5-2.9mm) for 868 and later models.
    4.  
    5. Remove the extension housing from the case.
    6.  
    7. Remove the mainshaft rear bearing, if it did not come off with the extension housing.
    8.  
    9. Remove the transmission case cover and gasket.
    10.  
    11. Remove the drive pinion bearing retainer.
    12.  
    13. When removing the drive pinion and bearing assembly from the transmission case, slide the front inner stop ring from the short splines on the pinion as the assembly is being removed from the case.
    14.  
    15. Remove the main drive pinion bearing snapring.
    16.  
    17. Press the bearing off the pinion shaft and remove the oil slinger.
    18.  
    19. Remove the mainshaft pilot bearing snapring from the cavity of the pinion gear.
    20.  
    21. Remove the 7 pilot roller bearings.
    22.  
    23. Remove seal from pinion retainer.
    24.  
    25. Remove the mainshaft rear bearing snapring from the groove in the mainshaft rear bearing bore in the case.
    26.  
    27. Remove the rear bearing snapring from the groove in the mainshaft rear bearing bore in the case.
    28.  
    29. Remove the synchronizer assembly from the case.
    30.  
    31. Remove the 2nd/3rd shift fork.
    32.  
    33. Remove the synchronizer clutch gear, snapring, clutch gear, 2nd gear, and 1st/reverse sliding gear from the mainshaft.
    34.  
    35. Withdraw the mainshaft and bearing out through rear of the case.
    36.  
    37. Remove the synchronizer clutch gear, 2nd gear, 1st/reverse sliding gear, and 1st/reverse shift fork from the case.
    38.  
    39. With a dummy shaft, drive the countershaft toward the rear of the case until the small key can be removed from the countershaft.
    40.  
    41. Remove the countershaft from the case.
    42.  
    43. Lift the cluster gear, the thrust washers and the dummy shaft assembly out of the case.
    44.  
    45. Dismantle the cluster gear, (88 rollers, four spacer rings and the center spacer from the cluster).
    46.  
    47. With a blunt drift, drive the reverse idler shaft toward the rear of the case far enough to remove the key from the shaft.
    48.  
    49. Completely remove the shaft from the case, then remove the idler gear.
    50.  
    51. Remove the thrust washers and 14 rollers.
    52.  
    53. With a small punch, remove the 1st/reverse gear lever shaft tapered lock pin by driving it toward the top of the transmission case.
    54.  
    55. Remove the 2nd/3rd gear lever shaft in the same manner.
    56.  
    57. Remove the lever shafts from the transmission case being careful not to lose the spring-loaded detent balls.
    58.  
    59. Remove the interlock sleeve, spring pin and detent balls.
    60.  
    61. Remove both lever shaft seals and discard same.
    62.  

    New Process A-745 Assembly
    1. Place the oil slinger on the main drive pinion with the offset outer portion next to the drive pinion teeth.
    2.  
    3. Place the main drive pinion bearing on the pinion shaft with the outer snapring away from the pinion gear.
    4.  
    5. Press the bearing into position so it is seated firmly against the oil slinger and pinion gear.
    6.  
    7. Install the bearing retaining snapring in its groove on the pinion shaft.
    8.  
    9. Heavily grease the 7 pilot bearing rollers and install them in the cavity at the rear of the main pilot drive.
    10.  
    11. Install the snapring.
    12.  
    13. Place the bearing spacer in the center of the bore in the cluster gear and use the dummy shaft to assist in assembling the roller bearings.
    14.  
    15. Install a row of 14 rollers next to one end of the spacer, using heavy grease to hold them.
    16.  
    17. Place one of the four bearing spacer rings next to the row of the rollers, and install another row of 14 rollers next to the spacer ring.
    18.  
    19. Install another spacer ring at the outside end of the 2nd row of bearing rollers.
    20.  
    21. At the opposite end of the cluster gear bore, install the remaining spacer rings and bearing rollers in the same sequence as listed in Steps 8, 9, and 1.
    22.  
    23. With a small amount of grease, install the front thrust washer on the dummy shaft at the front end of the cluster gear, with the tabs outward.
    24.  
    25. Install the tabbed rear thrust washer onto the dummy shaft against the rear of the cluster gear with the tabs inserted in the cluster gear grooves.
    26.  
    27. Install the remaining rear thrust washer plate onto the rear of the gear and dummy shaft with the step in the washer facing upward, as viewed from the rear.
    28.  
    29. Align tabs of the front thrust washer vertically to index the notches in the transmission case.
    30.  
    31. Using the countershaft, drive the dummy shaft forward, out of the case. Countershaft end-play should be 0.0045-0.0280 in. (0.11-0.71mm).
    32.  
    33. Position a dummy shaft in the reverse idler gear and, using heavy grease, install the 14 roller bearings into the gear.
    34.  
    35. Place the thrust washers at each end of the reverse idler gear, then place the assembly in the case with the chamfered end of the gear teeth toward the front.
    36.  
    37. Insert the reverse idler shaft into the rear case bore with the keyway to the rear, pushing the dummy shaft toward and out of the front of the transmission.
    38.  
    39. With the keyway in proper alignment, insert the key and continue driving the shaft forward until the key seats in the recess.
    40.  
    41. Install two new lever shaft seals in the transmission case.
    42.  
    43. Lubricate and install 2nd/3rd lever shaft in the bores of the case.
    44.  
    45. Install the 2nd/3rd lever shaft lock pin in the hole in the case.
    46.  
    47. Place interlock parts in the case in the following order: ball, sleeve, spring, pin and ball.
    48.  
    49. Enter low and reverse lever shaft in the case bore, depress the detent ball against spring tension and push the lever shaft firmly into position, in order to prevent the ball from escaping.
    50.  
    51. Install the 1st/reverse lever shaft lock pin in the case.
    52.  
    53. Place the 1st/reverse fork in the lever shaft, with the offset facing the rear.
    54.  
    55. While holding the low and reverse sliding gear in position in the fork, with the hub extension to the rear, insert the mainshaft with the rear bearing through the rear of the case and into the sliding gear.
    56.  
    57. Place the synchronizer stop ring spring, then the rear stop ring, on the synchronizer splines of the 2nd gear. Install the 2nd gear onto the mainshaft. Synchronizer shims must be added if synchronizer float is more than the maximum in Step 2 of disassembly. If float was less than minimum, the six pins must be shortened.
    58.  
    59. Install the synchronizer clutch with the shoulder to the front.
    60.  
    61. Select the thickest synchronizer clutch gear snapring that can be used, and install it in the mainshaft groove.
    62.  
    63. Check to see that clearance between clutch gear and 2nd gear is 0.004-0.014 in. (0.10-0.35mm).
    64.  
    65. Hold the synchronizer clutch gear sleeve and two outer rings together with pins properly entered into the holes in the clutch gear sleeve and with the clutch gear sleeve engaged in the groove of the 2nd and 3rd-speed shift fork, position the fork in the 2nd/3rd lever shaft.
    66.  
    67. While holding the synchronizer parts and fork in position, slide the mainshaft forward, entering the synchronizer clutch gear into the clutch gear sleeve and simultaneously entering the mainshaft rear bearing in the case bore.
    68.  
    69. While still holding the synchronizer parts in position, tap the mainshaft forward until the rear bearing bottoms in the case bore.
    70.  
    71. Install the mainshaft rear bearing snapring into place in the case bore.
    72.  
    73. Install a new drive pinion retainer seal.
    74.  
    75. Place the synchronizer front inner ring in position in the front outer ring, and enter the main drive pinion through the case bore.
    76.  
    77. Engage the splines on the rear of the pinion with the inner stop ring, and tap the drive pinion into the case until the outer snapring on the pinion bearing is against the transmission case.
    78.  
    79. Place the drive pinion bearing retainer over the pinion shaft and against the transmission case. While holding the retainer against the transmission case, measure the clearance between the retainer and case and choose a gasket 0.003-0.005 in. (0.07-0.12mm) thicker than this reading.
    80.  
    81. Torque the front bearing retainer bolts to 19 ft. lbs. (40 Nm).
    82.  
    83. Install a new extension housing seal.
    84.  
    85. Install extension housing and torque the bolts to 36 ft. lbs. (67 Nm).
    86.  
    87. Install the parking brake assembly, on vehicles so equipped.
    88.  
    89. Install the parking brake drum (if so equipped) and flange assembly and torque the nut to 95 ft. lbs. (237 Nm).
    90.  
    91. Install the drain plug in the transmission case.
    92.  
    93. Install the gearshift operating levers, and torque to 4 ft. lbs. (16 Nm).
    94.  
    95. Install the back-up light switch.
    96.  
    97. Install the speedometer cable and drive gear. Fill the transmission with lubricant.
    98.  

    Warner T-87 Series 3-Speed Disassembly

    See Figure 30

    The T-87 is a three-speed synchronized transmission having helical design gears. The gearshift lever on most models, is located on the steering column and the shift is transferred to the transmission through remote control rods. On some models, shifting is performed with a floor mounted lever.



    Click image to see an enlarged view

    Fig. Fig. 30: Warner T87E exploded view

    MAIN DRIVE GEAR AND MAINSHAFT
    1. Remove the gearshift housing cover from the case.
    2.  
    3. Remove the main drive gear bearing retainer from the shaft of the main drive gear.
    4.  
    5. Remove the brake assembly.
    6.  
    7. Remove the countershaft and reverse idler shaft lockplate and gasket from the transmission case.
    8.  
    9. Remove the rear bearing retainer and gasket.
    10.  
    11. Remove the cotter pin, nut, speedometer drive gear, and spacer from the mainshaft.
    12.  
    13. Remove snapring holding mainshaft bearing.
    14.  
    15. Pull bearing from mainshaft and remove oil baffle.
    16.  
    17. Drive the countershaft out through the rear of the case.
    18.  
    19. Pull the main drive gear as far forward as possible and lift the mainshaft out of the case.
    20.  

    CLUSTER AND REVERSE IDLER GEARS
    1. Remove the snapring from the main drive gear bearing. Tap lightly on the front end of gear shaft until bearing is free. Place hand over rear end of gear to prevent loss of pilot bearing and lift the main drive gear assembly from case.
    2.  
    3. Remove the cluster gear assembly from the case, and remove the thrust washers from both ends.
    4.  
    5. Remove the two countershaft bearings and the spacer from inside the gear assembly.
    6.  
    7. Drive the reverse idler shaft forward until the shaft is free and lift the gear and shaft out of the case.
    8.  

    Warner T-87 Series Component Disassembly
    MAINSHAFT
    1. Pull the sliding 1st/reverse gear from the mainshaft.
    2.  
    3. Remove the snapring, and slide the synchronizer unit and 2nd gear off the shaft.
    4.  
    5. Remove the synchronizer stop ring from the 2nd gear.
    6.  
    7. Slide the synchronizer gear out of the sleeve.
    8.  
    9. Remove the snaprings from each end of the hub and remove the three inserts.
    10.  

    The stop rings used with the synchronizer are removed separately. The rear stop ring is removed with the 2nd gear and the forward ring is removed with the main drive gear.

    MAIN DRIVE GEAR
    1. Remove the synchronizer stop ring.
    2.  
    3. Remove the mainshaft pilot bearing from inside the main drive gear.
    4.  
    5. Remove the snapring from the gear and pull or press the bearing off the gear.
    6.  
    7. Remove the oil baffle from the gear.
    8.  

    GEARSHIFT COVER
    1. Remove the nuts and plain washers from the inner ends of the two gearshift levers.
    2.  
    3. Tap the inner ends of the levers until the shifter cams are forced off the lever shaft. Carefully remove the cams, gearshift cam balls and selector ball springs.
    4.  
    5. Slowly remove the levers and remove the interlock pin from the housing.
    6.  
    7. Remove the snaprings and the gearshift forks.
    8.  
    9. Remove the gearshift lever oil seals from the top of the housing.
    10.  

    Warner T-87 Series Component Assembly

    Coat all parts with transmission lubricant to prevent scoring during initial operation.

    SYNCHRONIZER UNIT

    Slide the three inserts into the synchronizer gear and install the two snaprings on the ends of the gear. Slide the gear into the sleeve.

    MAINSHAFT
    1. Slide the 2nd speed gear and bushing onto the front end of the mainshaft.
    2.  
    3. Coat the synchronizer stop ring with grease and install on the shaft.
    4.  
    5. Install the synchronizer assembly on the shaft. Make sure the cut-outs on the stop ring coincide with inserts in the hub and install the snapring holding gear and synchronizer on the shaft.
    6.  
    7. Check the end-play between the 2nd gear and shaft spline shoulder. If the end-play exceeds 0.020 in. (0.50mm), replace any worn parts.
    8.  
    9. Install the sliding 1st/reverse on the rear end of the shaft.
    10.  

    MAIN DRIVE GEAR
    1. Install the oil baffle, bearing and small snapring on the main drive gear.
    2.  
    3. Grease the bore in the rear end of the shaft and install the mainshaft pilot bearing in the bore.
    4.  
    5. Install the synchronizer stop ring on the rear end of the gear.
    6.  

    COUNTERSHAFT AND GEAR SUB-ASSEMBLY

    Install the spacer and two countershaft bearings in the cluster gear. Grease the thrust washers and position on ends of cluster gear.

    GEARSHIFT COVER
    1. Install the gearshift lever oil seals on the top of the housing.
    2.  
    3. Replace the snaprings and the gearshift forks.
    4.  
    5. Install the levers and the interlock pin to the housing.
    6.  
    7. Reinstall the cams, gearshift cam balls and selector ball springs. Replace the shifter cams to the lever shaft.
    8.  
    9. Install the nuts and plain washers to the inner ends of the two gearshift levers.
    10.  

    Warner T-87 Series Assembly In Case
    REVERSE IDLER
    1. Position the reverse idler gear and shaft in the transmission case. This shaft is driven in until the forward edge of the retainer notch in the shaft is flush with the rear face of the case.
    2.  
    3. Install the front cluster gear end washer with the washer tip hooked into the groove on the inside of the case. Position the cluster gear assembly in the case with the large gear toward the front. Make sure all end washers remain in position.
    4.  

    MAIN DRIVE GEAR
    1. Coat the forward synchronizer stop ring with grease and position on the rear end of the main drive gear.
    2.  
    3. Install the main drive gear in the transmission case.
    4.  
    5. Install the snapring on the outside of the main drive gear bearing. Make sure the snapring is flush with the face of the case.
    6.  
    7. Position a new gasket on the front of the transmission case.
    8.  
    9. Install the main drive gear retainer.
    10.  

    MAINSHAFT
    1. Position the mainshaft assembly in the transmission case and install the oil baffle on the shaft.
    2.  
    3. Install the snapring in the bearing groove and drive the bearing onto the shaft until the snapring is flush with the face of the case.
    4.  
    5. Make sure that the synchronizer stop rings are free in the synchronizer assembly.
    6.  

    COUNTERSHAFT
    1. Raise the cluster gear assembly until the bearings in the assembly are aligned with the countershaft holes in the transmission case. Be sure the three washers are properly aligned.
    2.  
    3. Insert the countershaft into the hole in the rear of the case and push forward until the front edge of the notch in the shaft is flush with the rear face of the transmission case. The notch must also be aligned with the notch in the reverse idler shaft.
    4.  
    5. Install the countershaft and reverse idler shaft lockplate and gasket.
    6.  
    7. Install the rear bearing retainer and a new gasket.
    8.  
    9. Install the parking brake assembly on the rear bearing retainer.
    10.  

    GEARSHIFT COVER
    1. Position a new gasket on top of the transmission case.
    2.  
    3. Place the gearshift forks in neutral position.
    4.  
    5. The reverse/1st gearshift fork must be placed so that the smooth side of the fork is toward the gear. Otherwise the transmission will not shift into low gear.
    6.  
    7. Lower the housing assembly onto the transmission case seeing that the forks enter the proper channels in the sliding gear and the synchronizer sleeve.
    8.  
    9. Tighten the housing to case.
    10.  
    11. Install the drain plug.
    12.  
    13. Manually turn the projecting shaft to make sure that the gears do not bind, and that the shifters forks are in the proper position.
    14.  

    Warner T-87 Series Gearshift Control Adjustments
    CROSSOVER

    Before making the crossover adjustment, the gearshift lever shaft must be in its normal fully returned position in neutral.

    1. After removing the grease fitting from the tube lever pin retainer, rotate the retainer until the gearshift tube cross pin is exposed.
    2.  
    3. If a 0.04 in. (1mm) feeler (round gauge) cannot be inserted between the gearshift tube cross pin and the bottom of the slot in the 2nd-direct shift lever hub, then adjustment at the gearshift tube lower support must be made as follows:
    4.  
    5. Adjust the support up or down to the 0.04 in. (1mm) clearance. Tighten the supporting clamp screws to 60 inch lbs. (7.8 Nm).
    6.  
    7. Rotate tube lever pin retainer to original position and install the fitting at 60 inch lbs. (8 Nm). Failure to reinstall the fitting will result in the loss of the gearshift tube cross pin.
    8.  
    9. Proper adjustment should provide equal up and down free travel of the gearshift lever in either high or 2nd gear position. Check the crossover adjustment, at the manual lever, by making the crossover from 2nd/direct to 1st/reverse. Crossover movement should be free of interference. Crossover movement from 1st/reverse to 2nd/3rd likewise, should also be free of interference.
    10.  

    CONTROL ROD

    Place transmission in neutral before making adjustment.

    1. Loosen and back-off the adjusting nut at the 2nd/direct gearshift control rod swivel.
    2.  
    3. Turn both adjusting nuts in the direction required to locate the lever, at the steering wheel, with the center spoke in the true vertical plane. The gearshift lever should be directly under the right spoke of the steering wheel.
    4.  
    5. Tighten the adjusting nuts 60 inch lbs. (8 Nm) against the 2nd/direct control rod swivel block. Be sure the transmission remains in neutral.
    6.  
    7. Loosen and back-off the adjusting nut at the 1st/reverse gearshift control rod swivel.
    8.  
    9. Position the 1st/reverse gearshift lever in direct alignment with the 2nd/direct gearshift lever. Check by moving the manual lever through the crossover. Tighten the adjusting nuts securely to 60 inch lbs. (8 Nm) against the swivel block. Do not lubricate the swivel blocks. Incomplete engagement of the gears can damage the transmission.
    10.  

    GEARSHIFT HOUSING

    When disassembling the gearshift housing, place a cloth over the shift rail to prevent loss of detent ball and spring.

    1. Install the 1st-reverse shift rail part way in the cover assembly, part way in the detent ball and spring. Install the shift fork then drive the shift rail in remaining way.
    2.  
    3. Following the same procedure, install the intermediate and high shift rail and fork into the cover assembly.
    4.  
    5. Install the four expansion plugs, shift lever, cap, and retaining pin.
    6.  

    Warner T-87 Series Installation

    Position transmission in neutral, install new gasket and cover assembly on transmission. Tighten the cap screws to 24 ft. lbs. (47 Nm).

    Torque Specifications:


    Transmission-to-flywheel housing: 26-42 ft. lbs. (50-56 Nm)
     
    Transmission cover-to-case: 5-19 ft. lbs. (18-25 Nm)
     
    Speedometer cable retainer-to-transmission extension: 3-4.5 ft. lbs. (4-6 Nm)
     
    Transmission extension-to-case: 28-50 ft. lbs. (54-67 Nm)
     
    Flywheel housing-to-engine: 28-50 ft. lbs. (54-67 Nm)
     
    Filler Plug: 7-20 ft. lbs. (20-27 Nm)
     
    Drain Plug: 11-30 ft. lbs. (27-41 Nm)
     

    New Process NP-2500 5-Speed Disassembly

    See Figures 31 through 53

    1. Remove the transmission from the truck.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 31: External transmission components

    1. Remove the shifter assembly bolts.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 32: Remove the 4 shifter bolts

    1. The shifter assembly is sealed with a bead of RTV sealant so it must be pried loose before removal. Clean all RTV sealant from both mating surfaces.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 33: Pry the shifter assembly to remove

    1. Remove the access cover bolts.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 34: Access cover bolts need to be removed next

    1. The access cover is sealed with a bead of RTV sealant so it must be pried loose before removal. Clean all RTV sealant from both mating surfaces.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 35: Remove the access cover and notice the location of the detent springs

    1. Remove the detent springs and bullets with a magnet. Keep track of which is which.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 36: Make sure you use a magnet to remove the small springs and bullets, you do not want to loose any

    1. Remove the extension housing-to-case bolts.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 37: There are 8 extension housing bolts to be removed

    1. The extension housing is sealed with a bead of RTV sealant so it must be pried loose before removal. When pulling off the housing, hold the Reverse/Overdrive shift rail as shown in the accompanying illustration. Clean all RTV sealant from both mating surfaces.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 38: Notice the way to pull off the housing, by holding the reverse/overdrive shift rail

    1. Remove the Reverse/Overdrive shift rail and blocker spring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 39: Blocker spring position

    1. Remove the tapered pins from the shift forks.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 40: Use care removing the tapered pins from the shift forks

    1. Remove the 1st/2nd shift rail.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 41: Remove the inner lockplates to remove the 1-2 shift rail

    1. Remove the countershaft overdrive gear snapring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 42: Next, remove the countershaft overdrive gear snapring with a pair of snapring pliers

    1. Remove the countershaft overdrive gear, using tool C-4982.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 43: After removing the snapring, the countershaft overdrive gear can be removed with tool No. C-4982

    1. Remove the mainshaft overdrive gear snapring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 44: The mainshaft overdrive gear snapring can be removed next with snapring pliers

    1. Remove the mainshaft overdrive gear thrust washer and anti-spin pin.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 45: Next, remove the mainshaft overdrive gear thrust washer, then using the pliers, the anti-spin pin needs to be removed

    1. Remove the mainshaft overdrive gear.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 46: Remove the mainshaft OD gear

    1. Remove the Reverse/Overdrive hub snapring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 47: Reverse/overdrive hub snapring location

    1. Remove the Reverse/Overdrive synchronizer, fork, and rail assembly.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 48: Remove with ease the synchronizer, fork and rail assembly

    1. Remove the 3rd/4th shift rail.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 49: To remove and install the 3-4 shift rail do not forget the interlockplate

    1. Remove the 1st/2nd and 3rd/4th shift forks.
    2.  
    3. Remove the 1st/2nd and 3rd/4th shift rails.
    4.  
    5. Remove the Reverse gear.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 50: Slide the reverse gear out

    1. Remove the Reverse gear thrust washer.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 51: Thrust washers are small be careful when removing and installing them

    1. Remove the center support plate bolts.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 52: Loosen and remove the center support plate bolts

    1. Remove the gear set/support plate assembly.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 53: Gear set removal and installation

    New Process NP-2500 Gear Set Disassembly

    See Figures 54 through 73

    1. Open the mainshaft center bearing snapring with pliers and, using a plastic mallet on the center support, tap the mainshaft assembly out of the center support.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 54: Locations of gears



    Click image to see an enlarged view

    Fig. Fig. 55: Removing the mainshaft

    1. Remove the countershaft gear from the center support.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 56: Countershaft gear

    1. Remove the 3rd/4th synchronizer hub snapring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 57: 3-4 synchronizer snapring removal with snapring pliers

    1. Remove the 3rd/4th synchronizer assembly.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 58: 3-4 synchronizer assembly removal

    1. Remove the 3rd speed gear.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 59: Slide off third gear after 3-4 synchronizer

    1. Remove the split thrust washer and retaining ring from the mainshaft.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 60: This is what a split thrust washer looks like

    1. Remove the 2nd speed gear.
    2.  
    3. Remove the 1st/2nd synchronizer hub snapring.
    4.  
    5. Remove the 1st/2nd synchronizer assembly.
    6.  
    7. Remove the 1st speed gear.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 61: Chamfered side of snapring must face 1st speed gear

    1. The synchronizers may be disassembled by removing the energizing springs.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 62: Synchronizer identification

    1. Remove the mainshaft center bearing snapring.
    2.  
    3. Place the mainshaft in an arbor press and press off the mainshaft center bearing.
    4.  
    5. Unbolt the input shaft bearing retainer bolts.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 63: Removing the bearing

    1. Remove the retainer and discard the gasket.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 64: Retainer and gasket

    1. Remove the large input bearing snapring.
    2.  
    3. Remove the input shaft from the case.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 65: Angle the input shaft and withdraw it from the case

    There should be 10 roller bearings in the bore of the input shaft.



    Click image to see an enlarged view

    Fig. Fig. 66: Be careful not to drop this bearing, since 10 rollers may fall out

    1. Remove the small input shaft bearing retaining snapring.
    2.  
    3. Using an arbor press, remove the input bearing.
    4.  
    5. Separate the reverse idler shaft snapring from the center support plate.
    6.  
    7. Remove the reverse idler gear and shaft.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 67: Exploded view of the reverse idler gear

    1. Remove the countershaft center bearing snapring.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 68: Countershaft center bearing snapring



    Click image to see an enlarged view

    Fig. Fig. 69: Countershaft gear

    1. Using an arbor press, remove the countershaft center bearing.
    2.  
    3. Using tool C-4983-4 and adapter, remove the front bearing cone from the countershaft.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 70: Front bearing cone removal

    1. Using an arbor press remove the front bearing cup from the case.
    2.  
    3. Using tool C-4983-5 and adapter, remove the rear bearing cone from the countershaft.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 71: For rear bearing cone removal, you will need an adapter tool and C-4983-5



    Click image to see an enlarged view

    Fig. Fig. 72: Shim selection chart

    1. Using tools L-4454 and L-4518, remove the countershaft rear bearing cup from the extension housing.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 73: You may need special tools L-4454 and L-4518 for removing the countershaft rear bearing cup from the extension housing

    1. Remove the snapring and remove the extension housing ball bearing.
    2.  
    3. Remove the extension housing yoke seal.
    4.  
    5. Drive out the extension housing bushing.
    6.  

    New Process NP-2500 Gear Set Assembly
    1. Drive in a new extension housing bushing.
    2.  
    3. Install a new extension housing yoke seal.
    4.  
    5. Install the extension housing ball bearing and snapring.
    6.  
    7. Using an arbor press and tools C-4171 and C-4973, install the countershaft rear bearing cup in the extension housing.
    8.  
    9. Using and arbor press and tool C-4966, install the rear bearing cone on the countershaft.
    10.  
    11. Use an arbor press and tool C-4171 to install the front bearing cup in the case.
    12.  
    13. Using an arbor press and tool C-4967, install the front bearing cone on the countershaft.
    14.  
    15. With use of the arbor press and tool C-4171, install the countershaft center bearing.
    16.  
    17. Install the countershaft center bearing snapring.
    18.  
    19. Using a dial indicator, check the countershaft gear end-play with the assembly positioned in the case. End-play should be 0.001-0.005 in. (0.03-0.13mm). Select-fit shims are available in 0.0007 in. (0.02mm) increments in sizes from 0.05-0.09 in. (1.37mm-2.29mm).
    20.  
    21. Assemble and install the reverse idler gear and shaft.
    22.  
    23. Install the reverse idler shaft snapring on the center support plate.
    24.  
    25. Install a new input shaft retainer oil seal.
    26.  
    27. Using an arbor press and tool C-4965, install the input bearing.
    28.  
    29. Install the small input shaft bearing retaining snapring.
    30.  
    31. Install the input shaft in the case.
    32.  
    33. Secure the large input bearing snapring.
    34.  
    35. Install the retainer and new gasket. Torque the bolts to 13 ft. lbs. (28 Nm).
    36.  
    37. Secure the 10 roller bearings in the bore of the input shaft, making sure not to drop any. Hold them in place by coating them with heavy grease.
    38.  
    39. Place the mainshaft in an arbor press and press on the mainshaft center bearing.
    40.  
    41. Install the mainshaft center bearing snapring.
    42.  
    43. Assemble the synchronizers.
    44.  
    45. Install the needle bearings and snapring with the chamfered side of the snapring facing 1st gear.
    46.  
    47. Install the 1st speed gear.
    48.  
    49. Install the 1st/2nd synchronizer assembly.
    50.  
    51. Install the 1st/2nd synchronizer hub snapring.
    52.  
    53. Install the 2nd speed gear.
    54.  
    55. Install the split thrust washer and retaining ring on the mainshaft.
    56.  
    57. Install the 3rd speed gear.
    58.  
    59. Install the 3rd/4th synchronizer assembly.
    60.  
    61. Install the 3rd/4th synchronizer hub snapring.
    62.  
    63. Install the countershaft gear from the center support.
    64.  
    65. Open the mainshaft center bearing snapring with a pliers and, using a plastic mallet on the center support, tap the mainshaft assembly onto the center support.
    66.  

    New Process NP-2500 Main Component Assembly
    1. Install the gear set/support plate assembly.
    2.  
    3. Bolt the center support plate bolts. Torque them to 28 ft. lbs. (54 Nm).
    4.  
    5. Install the Reverse gear thrust washer.
    6.  
    7. Install the Reverse gear.
    8.  
    9. Install the 1st/2nd and 3rd/4th shift forks.
    10.  
    11. Install the 3rd/4th shift rail.
    12.  
    13. Install the Reverse/Overdrive synchronizer, fork, and rail assembly.
    14.  
    15. Install the Reverse/Overdrive hub snapring.
    16.  
    17. Install the mainshaft overdrive gear.
    18.  
    19. Install the mainshaft overdrive gear thrust washer and anti-spin pin.
    20.  
    21. Secure the mainshaft overdrive gear snapring.
    22.  
    23. Install the countershaft overdrive gear using tool C-4982.
    24.  
    25. Install the countershaft overdrive gear snapring.
    26.  
    27. Install the 1st/2nd shift rail.
    28.  
    29. Install the tapered pins on the shift forks.
    30.  
    31. Install the Reverse/Overdrive shift rail and blocker spring. The long end of the blocker spring faces forward.
    32.  
    33. Install the extension housing. The housing is sealed with a bead of RTV sealant rather than a gasket. Torque the bolts to 28 ft. lbs. (54 Nm).
    34.  
    35. Install the detent springs and bullets.
    36.  
    37. Install the access cover. The access cover is sealed with a bead of RTV sealant rather than a gasket.
    38.  
    39. Install the access cover bolts. Torque the bolts to 13 ft. lbs. (28 Nm).
    40.  
    41. Install the shifter assembly. The shifter assembly is sealed with a bead of RTV sealant rather than a gasket.
    42.  
    43. Install the shifter assembly bolts. Torque the bolts to 13 ft. lbs. (28 Nm).
    44.  
    45. Install the transmission.
    46.  

     
    AutoZone Logo