a. Transmission Disassemble
Transmission Disassembly^ Tools Required
- J 3289-20 Holding Fixture
- J 8763-02 Holding Fixture and Base
- J 8763-21 Balance Bracket for C-Clamp
- J 21427-01 Speedometer Gear Puller Adapter
- J 22912-01 Split Plate Bearing Puller
- J 23907 Slide Hammer
- J 24420-C Harmonic Balancer Puller
- J 26941 Bearing/Bushing Remover
- J 36509 Detent Spring Plug Remover
- J 36515 Assembly Pallet
- J 36515-15 Mainshaft Adapter
- J 36515-16 Countershaft Adapter
- J 36511 Oil Fill/Drain Plug Hex Bit (17 mm)
- J 36183 Press Tube
- J 36184 Press Tube Reducer
- J 36507 Shift Shaft Detent Bushing Remove and Installer
- J 36800 Shift Rail Bushing Remover
- J 36824 Transmission Adapters
- J 36825 Output Shaft Oil Seal Remover
1. Remove the two lower housing bolts.
Important: The J 3289-20 requires mounting securely on a sturdy workbench.
2. Assemble the transmission holding fixture to the transmission.
2.1. Install the J 36824 (1) and the J 8763-02 (4) to the J 8763-21 (3).
2.2. Install the J 8763-21 (3) to the J 3289-20 (2).
2.3. Place the transmission in the holding fixture and adjust the J 36824 (1) and the J 8763-02 (4) to support the transmission.
3. Using J 36511, remove the oil fill plug.
4. Place a suitable container under the transmission assembly in order to drain the remaining transmission fluid.
5. Using J 36511, remove the oil drain plug.
6. Remove the gasket material from the housing.
7. Remove the two reverse idler shaft support bolts
8. Remove the transmission housing vent. Do not remove the metal tube from the housing.
9. Remove the backup lamp switch.
10. Remove the shift shaft block out bushing pin.
11. Remove the vehicle speed sensor, O-ring, and bolt.
12. Using the J 36509 and the J 23907, remove the detent plug, spring, and detent plunger.
13. If 4WD vehicle, remove the output shaft seal using the J 36825 and the J 23907. Screw the J 36825 into one of the three perforated holes in the seal.
14. Remove the six bolts securing the main drive gear bearing retainer to the front case. Remove the retainer by screwing two of the removed bolts into the threaded holes in the retainer.
15. Remove the main drive gear snap ring.
16. Remove the bolts securing the front housing to the rear housing.
17. Drive the two dowel pins into the front housing.
18. Remove the front housing.
19. Remove the countershaft front bearing.
20. Remove the reverse idler shaft support. The idler shaft support will snap out.
21. Move all of the shift forks forward. Engage the 4th gear, the 2nd gear, and Reverse gear. Retain the shift lever detent plunger and spring.
22. Remove the shift shaft lever roll pin.
22.1. Rotate the shift shaft lever finger down.
22.2. Support the shift shaft end.
22.3. Drive out the roll pin.
22.4. Ensure that the roll pin clears the 2nd speed gear.
23. Shift all of the gears into neutral.
24. Engage the 5th speed gear.
Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.
25. Push the shift shaft into the housing.
26. Remove the shift shaft socket roll pin.
26.1. Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.
26.2. Support the shift shaft end.
26.3. Using a 5 mm (3/16 inch) punch, remove the roll pin. The roll pin will fall into the transmission housing.
27. Remove the following components:
27.1. The shift shaft
27.2. The shift shaft socket
27.3. The shift shaft lever
27.4. The shift shaft block out bushing
28. Rotate the 3rd/4th speed gear shift fork counterclockwise and remove the 3rd/4th speed gear shift fork from the transmission case.
29. If Rear Wheel Drive (RWD) vehicle loosen the three bolts on the rear of the housing. Do not remove the bolts.
30. Install the J 36515-15 on the input shaft.
31. Install the J 36515-16 on the countershaft.
32. Install the transmission to the J 36515.
33. Remove the transmission holding fixture from the transmission.
34. If RWD vehicle remove the three bolts on the rear of the housing.
35. If 4WD vehicle, remove the main shaft rear bearing snap ring.
36. Remove the rear housing (4WD shown). Tap the rear housing with a rubber mallet.
37. If RWD vehicle, remove the main shaft bearing retainer.
38. Remove the following components from the mainshaft assembly:
^ The two shift forks (1)
^ The reverse idler gear (2)
^ The countershaft rear bearing (4)
^ The countershaft (3)
39. If RWD vehicle, using the J 21427-01 and the J 24420-8, remove the speed sensor reluctor wheel from the rear of the main shaft.
Do not reuse the reluctor wheel after removal.
40. If RWD vehicle, remove the mainshaft rear bearing snap ring (1) and the mainshaft rear bearing (2).
41. Remove the mainshaft assembly from the J 36515.
Important: Leave the synchronizer ring on the 3rd/4th synchronizer assembly to prevent the synchronizer detent balls from popping out.
42. Remove the main drive gear and the main drive gear pilot bearing from the main shaft.
43. Remove the mainshaft snap ring.
44. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.
Important: When removing the synchronizer hubs use the J 22912-01 under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.
45. Using a hydraulic press and the J 22912-01 remove the 3rd/4th speed gear synchronizer hub assembly, the third speed gear and the synchronizer rings.
46. Remove the synchronizer assembly from the third gear.
47. Remove the 3rd speed gear needle bearing assembly (1).
48. Remove the following components:
48.1. The 2nd speed gear two piece thrust washer
48.2. The retainer ring
49. Remove the following components:
49.1. The 2nd speed gear
49.2. The 2nd speed gear needle bearing assembly
50. Remove the 2nd gear synchronizer snap ring from the main shaft.
51. Remove the following components for the 2nd gear synchronizer:
51.1. The synchronizer cone
51.2. The blocker ring
51.3. The reaction cone
51.4. The interim ring
52. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.
Important: When removing the synchronizer hubs use the J 22912-01 under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.
53. Using a hydraulic press and the J 22912-01 remove the 1st/2nd speed gear synchronizer hub and the 1st speed gear.
54. Remove the following components:
54.1. The synchronizer cone (5)
54.2. The blocker ring (4)
54.3. The reactor cone (3)
54.4. The synchronizer interim ring (2)
54.5. The 1st speed gear (1)
55. Remove the 1st speed gear needle bearing assembly
56. Turn the mainshaft over to work on the output end.
57. Remove the following components:
57.1. The 5th speed gear (3)
57.2. The 5th speed gear needle bearing assembly (1)
58. Remove the snap ring for the 5th gear synchronizer hub from the mainshaft.
59. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.
Important: When removing the synchronizer hubs use the J 22912-01 under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.
60. Using a hydraulic press and the J 22912-01 remove the 5th/Reverse speed gear synchronizer assembly and the reverse speed gear.
61. Remove the following reverse speed gear needle bearing assembly.
62. Remove the reverse speed gear drag seal.
63. Remove the 5th speed gear drag seal.