1. Transmission Disassemble

Transmission Disassemble





1. Remove the drain plug (34) and drain the transmission fluid.





2. Remove the backup lamp switch and washer (208) from the case.





3. Remove the output sensor (213) and bolt (215) from the rear extension housing.





4. Using a screwdriver, release the staking of the propshaft flange nut (126).
5. Remove the propshaft flange nut (126) and propshaft flange fluid seal (193).
6. Remove the propshaft flange (108).





7. Notice:
When releasing the staking, do not tap with a hammer. Excessive force may damage the bearing.

To release the staking, insert a screwdriver into the gap between the select shift lever retainer (42) and the rod.
8. With suitable pliers, rotate the select shift lever retainer (42) forward.
9. Use a magnet to remove the shift lever pin (41).





10. Remove the shift lever rod universal joint (40), damper (102) and select shift lever retainer (42) from the end of the shift selector.





11. Remove the 8 bolts (93) from the extension housing (86).
12. Remove the extension housing.





13. Remove the rear output shaft rear bearing spacer (191).
14. Remove the vehicle speed sensor drive gear (212).
15. Remove the locking ball (214).
16. Remove the main shaft bearing oil slinger (107).





17. Remove the 11 flange bolts retaining the clutch housing. This includes 8 bolts from the front and 3 bolts from the rear.





18. Remove the clutch housing hole plug (30) from the clutch housing.





19. Remove the following components:
^ the shift shaft detent plug (36)
^ the shift shaft detent spring (75)
^ the shift shaft detent pin (68)





20. Remove the 10 bolts (27) and retainer (209) from the rear case housing.

21. Notice:
Refer to Machined Surface Damage Notice in Service Precautions.

Using a soft-face hammer, separate the rear case housing from the intermediate case housing.
22. Remove the rear case housing.





23. Remove the 2 oil trough bolts (37) and oil trough (20).





24. Remove the oil trough pipe (19).
25. Remove the bolt (35) and gasket (32).





26. Notice:
Refer to Machined Surface Damage Notice in Service Precautions.

Using a soft-face hammer, separate the intermediate case from the front clutch housing.
27. Remove the intermediate case housing.





28. Remove the shift shaft selector lever.





29. Remove the rear output shaft (111), input shaft bearing (137) and blocking ring (121) from the 6th gear synchronizer assembly.





30. Remove the reverse idler gear bearing (136), reverse idler gear (205) and the reverse idler gear shaft (204).





31. Remove the 4 bracket bolts from the shift counter lever bracket.





32. Stretch snap ring on the front countershaft bearing. Maintain stretch.





33. Using a rubber hammer, tap on transmission front case in order to disengage the countershaft bearing's snap ring.





34. Stretch the snap ring on the rear input shaft bearing. Maintain stretch.





35. Hold the countershaft. Using a soft rubber hammer tap on the transmission front case in order to disengage the snap ring. Separate the input shaft and countershaft from clutch housing.





36. Remove the input shaft, countershaft and shift rails as an assembly.





37. Separate the shift rails, the input shaft and countershaft.