The Warner T-176 transmission is a constant mesh unit, synchronized in all forward gears and with one reverse gear.
See Figure 1
- Remove the transfer case from the rear of the transmission.
- Remove the shift control housing. Mark the location of the two dowel bolts in the housing.
- Drain the lubricant from the transmission, if not previously done. Remove the rear adapter housing.
- With a dummy countershaft tool, remove the countershaft from the transmission, front to rear. Allow the cluster gear to lay on the bottom of the case.
- Remove the rear bearing locating and retaining snaprings. Remove the rear bearing with a bearing remover tool or equivalent.
- Match mark the front bearing retainer to the case for easier installation, remove the retaining bolts and the retainer.
- Remove the locating and retaining snaprings from the front bearing. Remove the front bearing and the input shaft using a puller tool or equivalent.
- Remove the mainshaft pilot bearing rollers from the input shaft pocket. Engage the third speed synchronizer.
- Remove the mainshaft assembly by lifting the front of the shaft upward and out.
- Remove the cluster gear assembly from the case. Locate and remove any thrust washers and needle roller bearings from the case.
- Tap the reverse idler gear shaft from the case and remove the reverse idler gear and thrust washers.
- Separate the reverse idler gear from the sliding gear. Do not lose the needle roller bearings.
- Remove the third/fourth speed synchronizer snapring from the front of the mainshaft.
- Remove the third/fourth synchronizer from the mainshaft and slide the hub from the sleeve. Remove the inserts and springs. Inspect the blocking rings for wear and damage.
- Remove the third speed gear and the second speed gear snapring. Remove the second speed gear and the blocking ring. Remove the tabbed thrust washer.
- Remove the snapring from the first/second synchronizer hub. Remove the hub and the reverse gear with sleeve as an assembly. Match mark the hub and sleeve for assembly references. Remove the inserts and springs as the sleeve is removed.
- Remove the first speed gear thrust washer from the rear of the shaft and remove the first speed gear and the blocking ring.
- Assemble the first/second synchronizer hub, inserts and springs. Install the clutch sleeve. Be sure to position the spring ends 180 degrees apart.
- Install the assembled first/second speed synchronizer hub and the reverse gear with sleeve, on the mainshaft. Secure with a new snapring.
- Install the first speed gear and blocking ring on the rear of the mainshaft and install the first gear thrust washer.
- Install a new tabbed thrust washer on the mainshaft with the tab seated in the mainshaft tab bore.
- Install the second speed gear and the blocking ring on the mainshaft and secure with a new snapring.
- Install the third speed gear and blocking ring on the mainshaft.
- Assemble the third/fourth speed synchronizer hub, inserts, and springs. Be sure the spring ends are 180 degrees apart.
- Install the assembled third/fourth speed synchronizer on the mainshaft and secure with a new snapring.
- The measured end play between the snapring and the third/fourth speed synchronizer should be 0.004-0.014 in. (0.10-0.36mm).
- Load the reverse idler gear with the 44 needle roller bearings and a bearing retainer on each end of the gear. Install the sliding gear on the reverse idler gear. Install lubricated thrust washers into the case.
- Install the reverse idler assembly into the case and install the reverse idler gear shaft.
- Be sure to engage the thrust washer locating tabs in the case locating slots.
- Seat the reverse idler gear shaft roll pin into the counterbore in the case. The reverse idler gear end play should be 0.004-0.018 in. (0.10-0.46mm).
- Install the 42 needle roller bearings in the cluster gear, using the dummy countershaft as a bearing holder. Use of a petroleum jelly type lubricant is suggested to hold the bearings in place.
- Position the lubricated thrust washers in place on the inside of the transmission case. Position the thrust washer tabs in the tab slots of the case.
- Insert the countershaft into the rear case bore, just far enough to hold the rear thrust washer. Lower the cluster gear assembly into the case and align the gear bore with the case bore. Push the countershaft into the cluster gear, displacing the dummy countershaft out the front case bore hole. Do not completely remove the dummy countershaft.
- Measure the cluster gear end play which should be 0.004-0.018 in. (0.10-0.46mm). Correct as required and reinstall the dummy countershaft into the cluster gear, pushing the countershaft from the gear.
- Allow the cluster gear to remain at the bottom of the case until the input and mainshaft has been installed to provide the necessary assembly clearance.
- With the synchronizers in the neutral position, install the mainshaft assembly into the case.
- Install the front bearing part way on the input shaft and install the 15 roller bearing in the shaft pocket.
Do not use a heavy grease to hold the bearings in the pocket as the grease can plug the lubrication holes. Use only a petroleum jelly type lubricant.
- Position the blocking ring on the third/fourth synchronizer. Support the mainshaft assembly and insert the input shaft through the front bearing bore of the case. Seat the mainshaft pilot hub into the bearing pocket of the input shaft and tap the front bearing and input shaft into the case, using a soft faced hammer.
- When the bearing is fully seated, install the bearing retainer housing, but not the snaprings at this time.
- Install the rear bearing on the mainshaft and the bearing bore of the case. It will be necessary to seat the rear bearing further than the locating snapring would allow, so do not install the locating snapring until after the retaining snapring is installed.
- Remove the front bearing retainer housing and fully seat the front bearing on the input shaft. Install the retaining and locating snaprings. Install a new oil seal in the retainer housing and install on the transmission case.
- Install the locating snapring on the rear bearing, if not previously done.
- To install the cluster gear and countershaft, turn the transmission case on end with the input shaft down. Align the cluster gear bore and thrust washers with the case bores. Tap the countershaft into place and displace the dummy countershaft out the front of the case. Do not allow the dummy shaft to drop to the floor.
- Level the transmission case and install the extension adapter housing with a new gasket.
- Shift the synchronizer sleeves by hand to insure correct operation. Install 3.5 pints of lubricant into the case and install a new gasket on the shift housing flange. With the gears in the neutral position and the shift lever forks in their neutral position, install the shift lever housing in place on the transmission case.