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:

NOTE

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 clutch fork.

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 parts.

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.

TRANSMISSION SERVICE

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 present.

When it becomes necessary to change the trans- mission oil, the following procedure should be used:

1. 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.

2. 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.

3. 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.

4. 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 plug.

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 scheduled PM.

REVIEW 2 QUESTIONS

Q1. What material is most commonly used in casting a transmission case?

Q2. What four shafts are located in a manual transmission?

Q3. What are the two functions of the synchronizer?

Q4. What are the two types of shift linkages used on manual transmissions?

Q5. What type of equipment uses a sliding gear transmission?

Q6. If first gear ratio is 7.55 to 1, what is the gear ratio when the transmission is shifted into reverse?