1. Transmission Disassemble

Transmission Disassemble

Special Tools
* DT 47678 - Transmission Holding Flange
* DT 47678-10 - Transmission Holding Flange Adapter
* DT 49139 - Hub Remover Tool
* DT 49293 - Gear Select/Skip Shift Solenoid Socket
* J 6125-1B - Slider Hammer
* J 8433 - Universal Bridge Puller
* J 3289-20 - Holding Fixture
* J 22888-20A - Puller
* J 23907 - Slide Hammer
* J 36017 - Valve Seal Remover
* J 38416-B - Harmonic Balancer Remover
* J 39431 - 5th/6th Driven Gear Puller
* J 39431-3 - 5th Gear Puller Adapter Bolts
* J 41816 - Crankshaft Balancer Remover
* J 44873-3 - Mounting Bolts
* J 45012 - Holding Fixture

For equivalent regional tools, refer to Special Tools (Special Tools and Equipment).

Extension Housing Removal




1. Install the DT 47678 - flange (2) and the DT 47678-10 - flange adapter (3).
2. Mount the transmission on a workbench using the J 3289-20 - holding fixture (1).
3. Rotate the transmission into a horizontal position.
4. Remove the transmission drain plug and drain the transmission fluid.
5. Shift the transmission into NEUTRAL (N).




6. Remove the shift control cover bolts (1).
7. Remove the shift control cover (2).




8. Remove the gear select/skip shift solenoid (1) using DT 49293 - socket (2).




9. Remove the shift detent assembly (1).




10. Install the J 45012 - holder with the mounting bolts to the propshaft transmission yoke (3).
11. Using a socket wrench, remove the propshaft transmission yoke nut (1).
12. Remove the propshaft transmission yoke washer (2).




13. Using J 41816 - 3 jaw puller , remove the propshaft transmission yoke (1).




14. Remove the O-ring (1) from propshaft or propshaft transmission yoke.




15. Remove the rear extension housing bolts (1), retainers (2, 4) and the rear extension housing (3).

Reverse Speed Gear Removal




1. Remove the plug (1), spring (2), and shift detent roller (3).




2. Remove the shift guide rollpin (2). Drive into the housing and remove with guide.
3. Remove the offset shift lever (1).




4. Remove the retaining ring (1).
5. Using J 38416-B - 3 jaw puller , remove the speed sensor rotor (2).
6. Remove the locking ball (3).




7. Remove the rear bearing retainer ring (1).
8. Remove the spacer (3).
9. Remove the mainshaft rear roller bearing (2).
10. Remove the spacer (3).




11. Remove the retainer ring (1).
12. Remove the reverse gear thrust washer (2).
13. Remove the reverse gear (3).
14. Remove the reverse gear caged needle bearing (4).
15. Remove the reverse gear blocking ring assembly (5), which includes the following components:

1. Reverse drive gear inner cone (6)
2. Reverse drive gear outer cone (7)
3. Reverse gear blocking ring (8)

Reverse Shift Fork Removal




1. Remove the reverse synchronizer retainer ring (1).
2. Remove and discard the reverse shift fork retainer ring (2).




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 reverse shift fork and synchronizer (1) and inserts.
5. Pry to remove the reverse synchronizer hub.
6. Remove the locking ring (2).
7. Remove the two piece thrust washer (3).

Countershaft Gear Removal




1. Remove the reverse counter shaft retainer ring.




2. Remove the reverse countershaft gear (2) using J 22888-20A - puller (1).




3. Remove the 5th gear countershaft retainer and spacer.




4. Remove the 5th gear from the countershaft.




5. Remove the 5th gear needle bearing from the countershaft.




6. Remove the 5th gear spacer from the countershaft.




7. Remove the 5th and 6th gear synchronizer hub retainer ring from the countershaft.




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

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. Using the J 8433 - puller (3), J 39431 - gear remover (5), and the J 39431-3 - adapter bolts (4), remove the 5th/6th speed driven gear.




3. Remove the following 5th/6th synchronizer components:

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




4. Remove the synchronizer hub assembly (1).




5. Remove the following components:

1. The 6th speed drive gear synchronizer blocking ring
2. The 6th speed drive gear friction cone
3. The 6th speed drive gear inner cone




6. Remove the 6th driven gear, caged needle bearing, and 2 spacers from the countershaft.

Transmission Case Removal




1. Remove the clutch concentric actuator cylinder. Refer to Clutch Concentric Actuator Cylinder Replacement (Tremec) (Clutch Concentric Actuator Cylinder Replacement (Tremec))Clutch Concentric Actuator Cylinder Replacement (Aisin) (Clutch Concentric Actuator Cylinder Replacement (Aisin)).
2. Remove 9 of the 11 clutch housing to transmission case bolts (1).
3. Rotate the transmission into the vertical position.




4. Remove the last 2 clutch housing to transmission case bolts (2).
5. Remove the shift lever guide bolts (1).




6. Remove the magnets (1) from the transmission case.




7. Drive in the select control lever assembly pin.




8. Remove the transmission case (1) and the select control lever assembly (2) together as follows:

1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
2. Hold the select control lever assembly against the guide plate in order to prevent the release of the detent ball and the spring.
3. Remove the select control lever assembly (2) from the transmission case.

Oil Filter Removal





Remove the oil filter (1).

Shift Shaft Assemblies and Gear Cluster Removal




1. Pull up on the 3rd/4th shift fork assembly (2) and 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 (1).




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.
5. Remove the shift shaft assembly from the mainshaft.




6. Remove the 4th gear blocking ring assembly, which includes the following components:

1. 4th speed drive gear blocking ring (2)
2. 4th speed drive gear outer cone (3)
3. 4th speed drive gear inner cone (4)

7. Remove the input shaft (1).