Before installation, place a small amount of grease
in the pilot bearing and on the release bearing inner
surface. Now, the transmission is ready to be installed.
Basic transmission installation is as follows:
DO NOT place any lubricant on the end of
the clutch shaft input splines or pressure plate
release levers. Grease in these locations can
spray onto the clutch disc, causing clutch
slippage and failure.
1. Place the transmission on the transmissionjack.
2. Position the transmission behind the engine.
Ensure that the release bearing is in place on the
3. Carefully align the transmission and engine,
ensuring that the input and output shaft lines up
perfectly with the center line of the engine
crankshaft. If the transmission is slightly tilted,
it will not fit into place.
4. With the transmission in high gear, slowly push
the transmission into the clutch housing. You
may need to raise or lower the transmission
slightly to keep it aligned.
5. When the transmission is almost in place,
wiggle the extension housing in a circular
motion while pushing toward the engine. This
will help start the input shaft in the pilot bearing.
The transmission will then slide into position.
6. With the transmission bolted to the clutch cover,
install the rear support or cross member and
transmission mount. Reinstall the clutch
linkage, the transmission linkage, and any other
7. Adjust the clutch.
With the transmission installed and the clutch
adjusted, test-drive the vehicle for proper operation. If
the transmission is noisy, extremely loose, or binds, it
must be removed and disassembled for further
inspection and corrective action.
The manual transmission should have the oil level
checked at each PM. Recurrent low oil level indicates
that there is leakage around the oil seals.
If you notice foaming in the oil, drain the
transmission and refill it with clean oil. Foaming is
evidence that water or some other lubricant that will
not mix with the recommended transmission oil is
When it becomes necessary to change the trans-
mission oil, the following procedure should be used:
Before you drain the oil, clean around the drain
and fill plugs thoroughly. Both drain and fill
plugs should be removed to allow the oil to
Drain the transmission immediately after the
vehicle has been operated. The oil will then be
warm and will readily drain, taking along the
suspended contaminants as it drains.
Check the drained oil for any uncommon
foreign matter, such as large metal particles
(steel or brass). This is a good sign of internal
damage to the gears, bearings, or synchronizers.
If large particles are found, notify your shop
supervisor for further instructions.
Once the transmission has drained completely
and no large metal particles are found, you
replace the drain plug and refill the transmission
with the proper grade of oil until it reaches the
bottom of the fill plug. You then replace the till
Other than the periodic check required on the
transmission fluid, drain and refill are performed as
prescribed by the manufacturer. You should check the
bolts for tightness and inspect the case for damage each
REVIEW 2 QUESTIONS
What material is most commonly used in casting
a transmission case?
What four shafts are located in a manual
What are the two functions of the synchronizer?
What are the two types of shift linkages used on
What type of equipment uses a sliding gear
If first gear ratio is 7.55 to 1, what is the gear
ratio when the transmission is shifted into