Insert the tapered bearing (inner ring with baskets and rollers).
Insert the outer races of the tapered bearings into the gearbox housing.
The installation of the outer ring in the right (smaller) part of the housing should be performed according to Fig. 3.25.
Lock the outer ring from rotating by securing it to the housing.
Install a new axle shaft seal. The sealing lips should be on the inside of the gearbox and should be lubricated with oil before assembly.
If the secondary shaft roller bearing has been removed, a new oil deflector must be installed (Fig. 3.26).
Install the roller bearing using tool 16-020 (Fig. 3.27).
Bearings with double-sided baskets should be installed so that the back side of the basket is at the bottom. If necessary, you can use a chisel to cut the surface of the hole in the gearbox housing. The outer ring of the roller bearing is inserted into the hole prepared in this way.
This method is forced in conditions when there is no possibility of replacing the gearbox housing. The rigidity of the support in this case will be less than that obtained under normal installation conditions.
Install the complete differential housing into the left (large) part of the gearbox housing. The bearings must be generously lubricated with oil.
Install the reverse intermediate gear on the axle (Fig. 3.28). At the same time, place the forks in the groove intended for them.
Place both gearbox shafts together as shown in Fig. 3.29. Seize the forks in the grooves. Place the unit in the gearbox housing and push it towards the gearshift lock plate. This plate must be turned clockwise.
Insert the selector guide sleeve and install the first and second gear synchronizer forks on it. Secure the forks to the guide sleeve using retaining rings.
Place the magnetic insert into the gearbox housing (Fig. 3.30).
Install the left side of the housing with a new gasket. Pay attention to the correct installation of the magnetic insert.
Tighten the mounting bolts of the installed housing part, ensuring the correct tightening torque.
Secure the differential crown bevel gears from rotating. Fig. 3.31 shows the correct position of the mounting bolts for the installed housing.
Install the expansion rings on the outer rings of the ball bearings of the gearbox shafts (Fig. 3.32).
The snap rings in the spare parts kits come in three different thicknesses. You need to select a ring that fits snugly into the bearing groove.
Install the gearbox housing.
Lubricate the working surface of the hub of the fifth gear drive pinion with FORD SAM-1C9 107A paste.
Note: The spline surfaces of the gear and shaft must be marked with the same color.
Insert the fifth gear onto the shaft. The shaft must be supported and secured from below during this operation.
Install the retaining ring using special tool 16-031 (Fig. 3.33).
These rings in the spare parts kits come in three different thicknesses. It is necessary to select a ring thickness that will ensure a tight fit of the ring in the groove.
Mount and install the synchronizer clutch on the driven gear of the fifth gear together with the synchronizer. The synchronizer must be complete with forks (Fig. 3.34). The clutch is selected in the manner described earlier.
Insert the bolt pin and spring into the fifth gear housing. Tighten the cap nut firmly (Fig. 3.35).
Insert the deadbolt pins and springs into the gearbox housing.
Both deadbolt systems must be installed before the fork rods are set to the correct positions.
Install the fifth gear forks and adjust the setting as follows:
- set the selector to the middle position.
- press the fifth gear rod down and turn it clockwise.
- engage fifth gear with the gearbox selector; to do this, turn the selector clockwise and at the same time pull it out completely (Fig. 3.36).
- use the forks to move the synchronizer clutch to the driven gear of the fifth gear.
- press the selector down and turn it clockwise until it stops,
- raise the selector finger so that there is no gap between the fifth gear crossbar and the top of the finger.
- in this position, tighten the finger clamp bolt.
Install the gearbox cover with a new gasket.
Check the operation of the gear shift mechanism by engaging all gears in turn.
Install the release bearing and the shaft with the clutch release forks.
Screw the bracket to the gearbox.