2. Install the gear assembly and shift fork into the bearing carrier.
3. Drive the outer part of the tapered roller bearing onto the end of the shaft, while doing this, make sure that the gear selector shaft is not pinched.
4. Install the gear control clamp on the shift rod, align the hole with the hole in the shift rod, insert the roll pin.
5. Install the reverse gear and segment into the bearing carrier, then slide the reverse gear shaft.
6. Install the input shaft assembly in the box without the bearing.
7. Pull back the 3/4 shift shaft until the 3/4 shift fork is in the groove in the synchronizer hub bushing. Move the shift rod to neutral position, align the hole in the shift rod with the hole in the fork. Support the free end of the shaft as you did when removing the shift fork and insert the pin.
8. Install a new gasket to the gearbox housing, slide the bearing carrier with the input and output shaft assemblies towards the gearbox housing. Align the holes and insert the dowel pin. Insert and tighten the bolts.
9. Install the input shaft ball bearing on the end of the shaft with the closed side of the bearing housing facing the bearing carrier. Drive in the bearing.
10. Install the thrust washer and circlip on the input shaft bearing.
11. Pull back the two shift rods to engage 1st gear and reverse, locking the shafts together. Install the output shaft nut, tighten it to the torque specified in Specifications and lock the nut on the shaft. Move the selector shafts back to their neutral position and check that both shafts turn freely.
12. Very carefully extend the 3/4 shift rod just enough to fit the small lockout piston. Lubricate the plunger, insert it into the hole, and insert the shift rod back. If the rod is extended too far, the synchronizer hub locking cotters may pop out.
13. When installing the switch housing on the main body, use a new gasket.
14. If the input shaft bearing or pinion bearing has been replaced, calculate the thickness of the new shims to be installed behind the bearing. To do this correctly, the bearings must be fully inserted into their seats, then measure the protrusion of each bearing from the face of the carrier housing (Pic. 6.14). Then measure the depth in the switch housing for each bearing (Pic. 6.15). Determine the required shim thickness by subtracting the bearing projection from the recess depth and adding 0.3 mm. Having determined the required thickness, you can purchase new gaskets.
15. When installing the shift housing, first check that the gaskets are installed in the housing with the recess towards the spring.
16. Install the spring by placing it inside the selector lever. Compress the spring and insert the inner selector lever into the housing so that the end of the spring is against the end of the housing and gasket. Move the spring and selector lever into the housing as far as possible (Pic. 6.16).
17. Insert the selector lever pin into the slots in the gear shift rods, install the shift housing in place. Insert the bolts, tighten them with the tightening torque specified in Specifications.
18. Lower the differential into the final drive housing with the crown teeth lining inward. Install the o-ring on the cover, place the cover on the casing. Insert the bolts, tighten them evenly in a diagonal sequence with the tightening torque specified in Specifications.
19. Insert the drive flanges on each side of the differential, tighten the bolts.
20. Fill the gearbox with oil.
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