First you'll need some engine oil to lubricate the various parts during assembly and a stand approximately 12" high with a hole in its centre large enough to accommodate the diameter of the input drive shaft.
Cover the stand with some clean lint-free cloth. Ensure the input shaft assembly's internal oil passage is clear and place it, front-end down, through the hole.
Fit the 1.75" dia x 0.700" 3rd gear drum thrust washer/bushing to the input driveshaft, lip facing downwards:
Place the 3rd gear drum over the thrust washer/bushing, engaging the drum's internal teeth with the top gear clutch plates' outer tongues:
Fit the 1.375" dia x 0.705" 3rd gear drum thrust washer/bushing in the annular cavity formed between the drum and the shaft:
Fit the 2.375" outer dia. x 1.875" inner dia. 3rd gear planet carrier thrust washer over the 3rd gear sun gear, lip facing upwards:
Fit the 3rd gear planet carrier, annulus teeth facing upwards, by engaging the planet gears with the 3rd gear sun gear:
Fit the 2.375" diameter double-lipped thrust washer to the rear of the 3rd gear planet carrier with the larger diameter lip facing downwards:
Fit the 2nd gear planet carrier assembly, engaging the annulus teeth with the 3rd gear planets and the 2nd gear planets engaging the internal teeth of the 2nd gear brake drum:
After fitting the 2nd gear planet carrier the rear teeth will stand proud of the drum.
fit the 1st/2nd sun gear to the shaft with its splines offset towards the rear of the gearbox and engage it with the 2nd gear planets:
Fit the 1st/2nd sun gear rear thrust washer:
Fit the 2.75" dia. 2nd gear planet carrier rear thrust washer, lip facing downwards:
Fit the 1st gear planet carrier, engaging the planet gears with the 1st/2nd sun gear:
Fit the 2.25" dia x 0.450" 1st gear planet carrier rear bushing/thrust washer:
Fit the 1st gear drum, engaging the annulus teeth with the 1st gear planet gears:
Fit the 2.125" dia. thrust washer/bushing to the annular cavity of the 1st gear drum:
Fit the reverse gear planet carrier, engaging the planet gears with the reverse sun gear:
Finally, fit the reverse gear drum. (The inner thrust washer/bushing is pressed into the drum and should not be disturbed unless it requires replacement.)
Clearances between the drums with new bushes/thrust washers fitted should be:
However, if you're not renewing the bushes/thrust washers the clearances may fall slightly below these limits. I wouldn't like to go lower than the 1st/2nd drum minimum of 0.003", but if the other minima are no more than 0.002" under these figures I personally wouldn't be too concerned.
All thrust washers, bushings and epicyclic gears fitted throughout the running gear are not interchangeable and it's impossible to fit them incorrectly. Dimensions quoted are taken from used parts, so although not to print size they will suffice for the purposes of identification.
© S.J. Moore January 2008