Secondary shaft assembly
After installing the 1st gear pinion, install the 1st and 2nd gear synchronizer and the retaining ring. Make sure that the annular groove of the synchronizer clutch is on the 2nd gear pinion side. The 3rd gear pinion retaining rings are available in three thicknesses; select the ring according to the groove size. The adjusting rings for the secondary shaft bearing are also available in three thicknesses. The groove of the outer bearing ring into which the adjusting ring is installed must face outward.
Gearbox assembly
After installing the intermediate reverse gear, engage the shaft gears (Fig. 3.39), insert the forks into the grooves of the couplings and install the shafts in the gearbox housing.
Install the fork axle, axle bushing, bushing retaining rings and locking bracket. Install the magnetic washer in place. Install a new gasket on the gearbox housing, make sure the magnet is positioned correctly and tighten the gearbox housing to clutch housing fastening bolts. Secure the rear support bracket to the gearbox housing. Select shaft bearing adjusting rings of suitable thickness, place a wooden spacer on the housing and, lifting the shafts with a screwdriver resting on the spacer, install the adjusting rings in the annular grooves of the outer bearing rings. Install the 5th gear housing. Position the adjusting rings as shown in Fig. 3.40.
Tighten the Y-gear housing mounting bolts. Lubricate the groove of the 5th gear pinion retaining ring. The marks on the gear edge and the shaft central hole must be the same color. Install the 5th gear pinion on the primary shaft, using tool 16.031 install a new retaining ring of suitable thickness. Install the 5th gear driven gear together with the synchronizer and engagement fork on the secondary shaft and secure it with a retaining ring of a thickness corresponding to the groove. Install the pin and spring and tighten the 5th gear engagement pinion retainer, having first applied sealant to the retainer.
Install the 5th gear engagement mechanism in place and adjust it as follows: set the gear selection rod to the neutral position, turn it clockwise until it stops and pull it towards you; push the synchronizer sleeve and fork onto the 5th gear. Use a screwdriver to turn the gear selection rod clockwise until it stops, press it down and hold it in this position (Fig. 3.41); lift the 5th gear engagement finger so that there is a gap between the finger and the 5th gear stop: holding all parts in this position, tighten the tension clutch nut.
Complete the gearbox assembly as described for the four-speed gearbox.
Removal, installation and adjustment of the gear shift drive
To facilitate adjustment of the drive, engage reverse gear (not 4th gear). After installing the gearshift lever cup, engage reverse gear.
The material was copied from an information website FordBook