4)Engage reverse gear.
5)Guiding the two engine mounting studs through the pinion bearing bolt holes in the main case, (the studs also keep the shim in correct alignment). Insert the transmission into the main case. Use a new gear carrier gasket of course. Tap the pinion bearing into its seat using a rubber mallet. On newer models carefully align the pinion bearing and its opening in the main case before inserting the transmission into the main case.
6)On older models remove the engine mounting studs and install the four retainer bolts with their lock plates. High performance trans rebuilds should have steel washers and bolts installed with red loctite. Torque bolts to 36 ft. lbs. On newer models install round pinion retainer and torque. If special tool is not available seat firmly using a drift.
7)Install new clutch main shaft seal.
8)Oil the seal and then insert rear main shaft through it.
9)Slide snap ring onto shaft. Then slide main shaft reverse gear (with the gear side toward the transmission) onto the shaft so that its past the shaft end and on the shaft as far as it will go.
10)Screw the main shaft halves together. Tighten finger-tight then back off until the splines align.
11)Slide the reverse gear over the main shaft joint and engage it with the idler gear. (If the reverse gear is a sloppy fit, the rear shaft will wobble at high speed - this will cause clutch seal failure.)
12)Tighten the gear carrier case nuts to 14 ft. lbs.
13)Press the differential bearings into the side plates (swing axle models). Install the differential with correct shims, side plates and axle assemblies.
WHEN INSTALLING THE TRANS NOTE THE FOLLOWING:
Bad transaxle mounts can cause jumping out of gear. Visually inspect the two rear bonded mounts and the front mount. Inability to shift and sloppy shifting can be caused by improper shift linkage adjustment. The two bolts that secure the shift lever ball housing (located under the shift boot) may be loose. The shift linkage rod coupling (located under the oval access cover plate on transmission hump under back seat) may be loose, or not fully coupled. This will keep the gears from fully engaging.
YEAR DIFFERENCES IN TUNNEL STYLE BOXES
1)The rear track has been widened approx. 2" starting with 1967 models.
2)Tapered roller bearings are used on 1965 and later model pinion shafts instead of the double ball bearings used to that time.
3)Two stock ring and pinion ratios are available 4.375:1 and 4.12I:l and 4.125:1 the 4.125:1 ratio used on late 1966 and later sedans.
4)Sealing of the clutch shaft (main shaft) has been improved in post '66 transaxles by using an oil return groove cast into the case. There is a more efficient oil seal used also. The main shaft is slightly modified as a result. The improved oil seal is interchang able and can be used on earlier models.
5)Gearshift housings starting in '66 have a sealing ring for more efficient sealing of the shift rod. Back up light switch provisions are also incorporated into the later type housings.
6)The shift rod for first - second gear selection has been made longer on the '66 and later models.