1. Transmission Disassemble

Transmission Disassemble

Special Tools
* DT 48827 - Skip Shift Socket
* DT-49139 - Hub Remover
* J 3289-20 - Holding Fixture
* J 6125-1B - Slide Hammer with Adapter
* J 8433 - Universal Bridge Puller
* J 39431 - Gear Remover and Bolts
* J 44395-A - Transmission Holding Fixture
For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Extension Housing Removal




1. Remove the adapter plate bolts (1, 2, and 3).




2. Install the J 44395-A - holding fixture (2).
3. Mount the transmission on a workbench using the J 3289-20 - holding fixture (1).
4. Rotate the transmission into a horizontal position.
5. Remove the transmission drain plug and drain the transmission fluid.
6. Shift the transmission into neutral (N).




7. Remove the rear extension housing bolts and the rear extension housing.

Reverse Speed Gear Removal




1. Remove the rear bearing retainer ring.
2. Remove the spacer.
3. Remove the mainshaft rear roller bearing.
4. Remove the spacer.




5. Remove the retainer ring.
6. Remove the reverse gear thrust washer.
7. Remove the reverse gear.
8. Remove the reverse gear caged needle bearing.
9. Remove the reverse drive gear inner cone.
10. Remove the reverse drive gear intermediate cone.
11. Remove the reverse gear synchronizer blocking ring.

Reverse Shift Fork Removal




1. Remove the reverse synchronizer retainer ring.




2. Remove and discard the reverse shift fork retainer ring.




3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.




4. Remove the following parts in order:

1. The reverse synchronizer sleeve, shift fork, and inserts
2. Pry to remove the reverse synchronizer hub


Countershaft Gear Removal




1. Remove the counter shaft retainer ring.




2. Remove the countershaft gear.




3. Remove the countershaft retainer and spacer.




4. Remove the gear from the countershaft.




5. Remove the needle bearing from the countershaft.




6. Remove the spacer from the countershaft.

5th/6th Speed Driven Gear Removal




1. Remove the locking ring (1) and the two piece thrust washer (2).

Note: Ensure the remover tools are aligned level to pull the gear evenly off the shaft.

2. Install J 8433 - puller (3), J 39431 - remover and bolts (5) and J 39431-4 (4) on the 5th speed driven gear.
3. Remove the 5th speed driven gear.




4. Remove the retainer clip from the countershaft.




5. Remove the 5th/6th speed shift fork retainer ring.




6. Remove the following components:

1. The 5th/6th shift fork
2. The synchronizer sleeve
3. The synchronizer inserts
4. The speed drive gear synchronizer blocking ring
5. The speed drive gear friction cone
6. The speed drive gear inner cone




7. Install the DT 49139 - remover between the synchronizer hub assembly and synchronizer blocking ring.
8. Remove the synchronizer hub assembly with J 6125-1B - hammer.




9. Remove the following components:

1. The speed drive gear synchronizer blocking ring
2. The speed drive gear friction cone
3. The speed drive gear inner cone




10. Remove the 6th driven gear, caged needle bearing, and spacer.

Transmission Case Removal




1. Using DT 48827 - socket, remove the computer aided gear select solenoid.




2. Using DT 48827 - socket, remove the reverse lockout solenoid from the reverse lockout body.
3. Remove the O-ring seal from the reverse lockout solenoid and discard.




4. Remove the reverse lockout assembly bolt and the reverse lockout body.
5. Remove the O-ring seal from the reverse lockout body and discard.




6. Remove the shifter cover plate retainer bolts.
7. Remove the shifter cover plate.
8. Remove the spring and roller detent.




9. Remove the shift detent assembly.




10. Remove 8 of the 11 adapter plate to transmission case bolts.
11. Rotate the transmission into the vertical position.




12. Remove the 2 shift lever guide bolts.




13. Remove the magnets from the transmission case.




14. Remove the offset lever roll pin by using a punch to push the pin through the shift shaft.




15. Pry the transmission case from the adapter plate.
16. Remove the offset lever and the transmission case at the same time.
17. Remove the 6th gear spacer from the countershaft.

Guide Plate Removal




1. Remove the detent guide plate attaching bolts.
2. Remove the detent guide plate.

Reverse Lockout Assembly Disassemble





Warning

The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.

1. Remove the O-ring (8) from the body (1).
2. Remove the retainer ring (7) from the body (1).
3. Remove the reverse lockout inner spring (2).
4. Compress the reverse lockout plunger (6) and the collar (4) in a vise and remove the retainer ring (3).
5. Remove the reverse lockout plunger (6).
6. Remove the reverse lockout outer spring (5).
7. Remove the reverse lockout collar (4).

Shift Shaft Assemblies and Gear Cluster Removal




1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
2. Remove the 5th/6th and the reverse shift shaft assembly.




3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.




4. Remove the mainshaft and the shift shaft components as an assembly.

Note: When removing the shift shaft be careful not to lose the dowel pin.

5. Remove the shift shaft assembly from the mainshaft.




6. Remove the following components from the adapter plate:

* 4th gear synchronizer blocking ring
* 4th gear intermediate cone
* 4th gear inner cone
* Input shaft