Transmission Case Disassemble (Gen 1)

Transmission Case Disassemble (Gen 1)

Special Tools

* 3-9506289 - Universal Adapter

* J-810700 - Mainshaft Bearing Remover

* J-810704 - Center Bar Puller

* M-680770 - Universal Sliding Mallet

* R-0007758 - Holding Fixture

* R-0007770 - Holding Fixture Adapter Plates

* T-0307000 - Extractor and Driver Fixture

* T-9807671 - Slide Hammer

For equivalent regional tools, refer to Special Tools F13-5/F15-5/F17-5 (M26) - Manual Transmission.





1. Install both plates of the R-0007770 - holding fixture adapter plates to the transmission case assembly (1).





2. Install the transmission case, with the R-0007770 - holding fixture adapter plates (1) to the R-0007758 - holding fixture (2) and 3-9506289 - universal adapter.





3. Remove the 5th shift fork bracket retaining bolts (1).

4. Remove the 5th shift fork bracket assembly (2).





5. Remove the 5th gear synchronizing hub retaining ring (1).





6. Using the J-810704 - puller, remove the 5th gear synchronizer assembly (1).





7. Remove the 5th gear blocking ring (1).

8. Remove the 5th gear assembly, driven (2).

9. Remove the 5th gear bearing assembly (3).





10. Remove the 5th gear retaining ring (1).





11. Using the J-810704 - puller, remove the 5th gear, driving (1).





Note:
The parking pawl bolts are micro-encapsulated and may require that the transmission case be heated to 80°C (176°F) with a heat gun.

12. Remove the parking pawl retaining bolts (1).

13. Remove the parking pawl (2).





14. Using the M-680770 - sliding mallet adapter (2) and the T-9807671 - slide hammer (1), remove the 4 shift shaft detent sleeves (3-6) from the transmission case.





Note:

* The bolts are micro-encapsulated and may require that the transmission case be heated to 80°C (176°F) with a heat gun.

* Engage the shift shafts into 3rd gear and 5th gear as indicated with arrows to remove the interlock pin connector.

15. Remove the shift shaft interlock pin connector bolts (2).

16. Remove the shift shaft interlock pin connector (1).





17. Remove the reverse shift fork pin (3).

18. Remove the reverse shift shaft (1).

19. Remove the reverse shift fork (2).





20. Use a block of wood (1) to relieve the pressure on the gearshift rod guides.





21. Remove the 3rd and 4th shift fork pin (3).

22. Remove the 3rd and 4th shift shaft (1).

23. Remove the 3rd and 4th shift fork (2).





24. Remove the 5th shift blocking guide (1) from the transmission case.





25. Remove the gearshift rod (1) from the transmission case.

26. Insert a block of wood (2) to relieve pressure on the gearshift rod guides.





27. Remove the 1st and 2nd shift fork pin (3).

28. Remove the 1st and 2nd shift shaft (1).

29. Remove the 1st and 2nd shift fork (2).





30. Remove the input shaft bearing retaining ring (1) from the bore, and leave it on the shaft.





31. Remove the transmission case from R-0007770 - adapter plates and install onto the T-0307000 - fixture.

Note:
Be prepared to support the reverse idler gear, input shaft and mainshaft as they are pressed from the case.

32. Support the mainshaft (3), input shaft (2) and reverse idler gear (1) while pressing the shafts from the case.





33. Remove the input shaft (4), reverse idler gear (3) and mainshaft (2) from the T-0307000 - fixture.

34. Remove the 5th gear bearing race (1) from the transmission case.





35. Remove the mainshaft bearing retaining ring (1).





36. Using J-810700 - mainshaft bearing remover, remove the mainshaft bearing (1) from the case.





37. Remove the reverse idler gear shaft (1) from the case.

38. Remove the reverse idler gear shaft retaining ball (2).