17

1)put the shifting plates in place and install the two snap ring springs. The snap ring springs should be offset to one another and the ends of each ring engaged behind the shifting plates. The driving flanks of the teeth on the third gear side of the
synchro hub are set back slightly to keep third gear from popping out. Third and fourth gears on the main shaft are each an assembly of three parts. The external teeth on the synchronizers engage the teeth on the third - fourth speed clutch gear which drive third -fourth gears. These two assemblies are pressed together with a thin washer between.
2)Insert the woodruff key in the main shaft and place third gear synchronizer ring on the cone of the gear.
3)Press the third - fourth synchro hub into position. The third gear side has an internal chamfer. The synchro hub must be positioned with the identifying number 4 toward fourth gear. Lift third gear a little and turn until the synchro ring engages in the shifting plates.
4)End play is checked between second gear and third gear on the main shaft. It should be .010" - .015".
5)Fourth gear, its needle cage and thrust washer can now be assembled onto the main shaft. (Note: Later model thrust washers have oil grooves and are best choice if available.)
6)End play is checked by measuring between thrust washer (while held against bearing race) and fourth gear. It should be between .OlO"- .015".

ASSEMBLY OF GEAR CARRIER CASE

1)Insert detent springs and balls into their bores.
2)Insert the shortest shift rod into the bore closest to the main shaft ball bearing. (Third - fourth gear.) The detent spring and ball can be compressed to allow the shaft to slide in if you use a new unsharpened pencil inserted down through the spring bore.
3)Insert an interlock plunger in the side bore between the installed shift rod and the middle shift rod bore. (Oblong balls are inter lock plungers.)
4)Install the longest shift rod into the middle bore with its detent ball and spring. (First - second gear.)

5)Insert the other interlock plunger between this rod and the next shift rod bore.

6)Install the last shift rod (reverse) and bolt the rocker arm guide onto it.

7)Insert rocker into the guide and into its pivot.

8) Check for correct interlocking by engaging one of the shafts as though you were selecting a gear. The shaft next to it should be locked.
9) Press the main drive shaft ball bearing into position.
10)Install pinion shaft needle bearing and secure it with the retaining bolt.
11)Before pressing the transmission shafts into the case position the selector fork for 3rd and 4th gears in the operating sleeve, hold the two transmission shafts together using a string or rubber band placed around the lst and 2nd gear operating sleeve on the pinion shaft and around the main shaft. Press on the main shaft guiding the pinion shaft into its bearing and also guiding the 3rd and 4th selector shaft into its shift fork. (The shift fork can be started onto the selector shaft prior to pressing.)
12)Install the first - second gear selector fork.