HOW TO: Upgrade to MDL Tail Housing MD-510-1000 & 1001

INSTRUCTIONS ON HOW TO REMOVE CURRENT TAIL HOUSING

& INSTALL NEW MDL Tail Housing MD-510-1000 & -1001

 

Here are the simple steps:

Transmission out of vehicle and oil drained.

With a 13mm socket – remove the shifter.

use a 5/32 punch – drive out the roll pin holding the offset block to the rail.

with a 15mm socket – remove 8 tail housing bolts.

Use a Hammer – knock off old tail housing hitting just below the shifter bolt threads, while holding the offset lever down with your thumb.

Inspect – case cover o-ring; should be soft and no cracks.

with an 8mm socket – remove case cover bolts

Use a  Large flat-tip screwdriver – pry up on opposite corners until the cover is loose and SLIDE cover to the passenger side and lift up.

Inspect – nylon fork pads.

Pay Attention – to the position of the ring around the selector’s finger in the case cover: All the steps go against the case cover.

use a 5/32 punch – on the shift rail… from the neutral position turn the shift rail to raise the pointer finger up and slide the shift rail towards the back of the cover and then rotate down and partially drive out the SHORT roll-pin. Rotate up and finish driving out the short roll pin.

Clean – all mating surfaces and oiled surfaces with carb cleaner.

File – as necessary mating surfaces to remove high spots.

Clean – all mating surfaces.

Silicone – Permatex Ultra-Grey or Ultra- Black:  apply a bead, even it out with your finger along a single mating surface.   No gaskets.

Installation is the reverse of removal.

 

Shim check – once tail and cover are re-installed, use a dead-blow hammer to set the input shaft and main shaft bearings by smacking them each a couple of times.

Grab the input shaft and bearing retainer, try and wiggle side-to-side.

Rotate input shaft in both directions 2-3 full turns.

No side-to-side movement and input shaft spins/rotates freely… no re-shimming required.

No side-to-side movement and the input shaft is difficult to turn… remove shims.

Yes, there is a side-to-side movement… add shim.

 

Shimming – Remove 4 bolts in the retainer, pry off retainer, maintain input shaft in trans.

Clean – all mating surfaces.

Add or remove shim based on shim check.

Install bearing retainer and TWO opposite bolts snug.

Repeat shim checks until there is no side-to-side movement and input shaft spins/rotates freely.

 

Remove the retainer and two bolts.

Clean – all mating surfaces.

Apply Silicone sealant inside the bolt circle.

Apply sealant to threads of bearing retainer bolts.

Install bearing retainer and FOUR bolts.

Torque 12-15 ft lbs.

Use a dead-blow hammer to set the input shaft and main shaft bearings again by smacking them each a couple of times.