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Figure following name of part indicates quantity necessary for one complete assembly.

Figure following name of part indicates quantity necessary for one complete assembly.

Figure 4D-6. Foot Shifter Cover - Exploded View

Remove cam shaft lock screw (23) from left side of shifter cover joint face. Engage head of old valve in notch in cam shaft and tap end of valve stem to pull cam shaft (24) from cover. Shifter cam (26) may be lifted out of cover.

Remove cotter pin (27) from end of shifter shaft. Remove shifter gear (28) and spring (29) from shaft and pull shaft (30) out of cover (31).

CLEANING, INSPECTION AND REPAIR (FIG. 4D-6)

Clean all parts except gaskets (8 and 17), and neutral indicator switch (18) in grease solvent. Clean switch with "Gunk" or gasoline.

Inspect fit of shaft (30) in bushings (32 and 33). If there is considerable side play, replace bushings. Pawl carrier bushing (32) may be pressed out of carrier on arbor press. Shifter shaft bushing (33) is removed as follows: Thread 5/8 in. tap into bushing about 1/2 in. deep. Remove tap and heat shifter cover around bushing to about 300 degrees. Quickly replace tap and clamp tap handle in vise. With rawhide mallet, tap cover near bushing until cover is driven off bushing. Insert new bushing with arbor press or soft metal hammer and wood block. Be sure bushing shoulder is seated against cover.

Inspect teeth on shifter gear and cam. Replace badly worn parts.

Inspect neutral indicator switch. Depress plunger in base of body. It should spring back without a bind. If panel light fails to light in neutral position, plunger is sticking. Switch cannot be repaired, it must be replaced. Do not test switch by passing current through it without having a neutral indicator panel light bulb in the circuit in series.

Inspect all springs. Inspect tips of cam follower (22) and shift pawls (10 and 11). If tips are rounded and worn, replace parts. To function properly these parts must have reasonably sharp tips.

Inspect all parts generally for cracks, bent parts and any wear that would impair intended functions. If hole in pawl carrier is elongated, bushing (32) must be replaced or mechanism will not shift properly.

ASSEMBLING SHIFTER COVER (FOOT SHIFT) (FIG. 4D-6)

It is necessary to time the shifter shaft (30) to the shifter gear (28), and the shifter gear to the cam gear on the shifter cam (26). If this is not done correctly, it will be impossible to shift into all gears.

Notice that the timing mark (Fig. 4D-7) cut between the center teeth on one side of shifter gear is in line with the corner of the squared shaft end and just a little to the left of the last ratchet tooth on the shifter shaft. This is the proper timing alignment.

Refer to Fig. 4D-6. Position shifter gear (28) and spring (29) in case, so side of gear with timing mark is toward case. Insert shifter shaft (30) so parts are timed as described above and tap parts together. Insert cotter pin (27).

Install shifter cam (26) in cover so ground timing mark on top of a tooth registers with timing mark on shifter gear. Slip oil seal (25) on widest of two grooves on end of cam shaft (24) and insert in cover, passing it through shifter cam. Secure shaft with lock screw (23).

Install cam follower (22), spring (21), retaining washer (20) and retainer (19). Install neutral indicator switch (18) and check to make sure button on shifter gear contacts plunger in base of switch.

Position cover (31) in vise with shifter mechanism end upward. Place gasket (17) and adapter plate (16) over cover. Insert adapter plate bracket screw (14) and washer (15) in hole directly above end of shifter gear but do not tighten. Shift gear shift cam to any position but neutral. Rock cam back and forth to make sure spring loaded cam follower is seating exactly in one of the indexing notches, or "V's," that determine cam position for one of the four gears.

Rotate adapter plate until timing notch (Fig. 4D-8) in adapter plate, located at bottom of shifter gear hole, lines up with notch between two bottom shifter gear teeth. Make alignment exact, then tighten adapter plate bracket screw to lock in position.

Apply a light coat of "Grease-AU" grease to curved springs (13) and insert them in slots on adapter plate. Grease ratchet end of shifter shaft. Lubricate pawls (10 and 11) with light oil after checking to see if they are free in holes in pawl carrier (9). Install pawl springs (12) and pawls in pawl carrier so notches in ends of pawls face inward or toward each other.

Install pawl carrier with pawls over end of shifter shaft with lug on pawl carrier inserted between ends of pawl carrier springs.

Figure 4D-7. Timing Shifter Gear

Figure 4D-8. Timing Shifter Notches

Figure 4D-9. Shifter Fork - Exploded View

I V? 11

1. Lock screw

2. Shifter fork shaft

3. Rubber oil seal

4. Shifter finger rollers (2)

7. Spacing shim (variable number)

8A. Shifter fork (3-speed, reverse only)

9. Standard spacing shim (2)

10. Spacing shim (variable number)

11. Shifting finger (2)

12. Shifting fork bushing (2)

Figure following name of part indicates quantity necessary for one complete assembly.

Lubricate back of pawl carrier with "Grease-All" grease and install cover gasket (8) and cover (7) so notches at top line up with corresponding notch on adapter plate. Apply Loctite sealant, Part No. 99619-60, to threads of shorter screw (5) and insert through bottom hole. Secure with nut (6) on back of adapter plate. Apply Loctite sealant to threads of five long screws (4) and tighten all screws.

Position cover dust shield (3) over dowel pins on pawl carrier. Position shifter shaft lever (2) over dowel pins and secure with three shifter shaft lever screws (1). Also treat the threads of these screws with Loctite sealant before inserting.

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