Disassembly/Assembly

Fig. 1 Exploded view of transmission & clutch housing assembly:

DISASSEMBLY

1. Separate the transmission from the transaxle, then remove the adapter cover, cover gasket, air breather, spring pin and transfer case adapter from transmission.
2. Remove seal ring, first and second gear shift jaw, third and fourth gear shift jaw and fifth and reverse gear shift jaw.
3. Remove gear shift lower case assembly, clutch housing assembly, oil seal, transmission power take off cover and gasket.
4. Unstake, then remove locknut (15) using a chisel.

Fig. 2 Exploded view of transmission:

5. Remove lock piece, then the reverse shaft with a slide hammer. Remove O-ring, side washer, needle bearing and reverse gear.

Fig. 3 Bearing removal:

6. Remove snap rings (22, 24, 25, 27, 29 and 30), and ball bearings (23, 26, 28 and 31) using suitable snap ring pliers and bearing puller tool No. MD998056-A and MD998811 or equivalents. For installation purposes, organize bearings and snap rings in order of removal.
7. Remove mainshaft assembly, drive pinion, pilot bearing and countershaft assembly.


ASSEMBLY

1. Reverse order of disassembly as shown noting the following:

Fig. 12 Bearing installation:

a. Install bearing onto drive drive pinion with bearing installation tools No. MD99812, MD998814 and MD998817 or equivalents.

Fig. 13 Main shaft installation:

b. Install drive pinion in case with pilot bearing and snap ring (30), then insert mainshaft assembly from inner side of case and insert into pilot bearing part of drive pinion.

Fig. 14 Installing bearing into case:

c. Using bearing installation tools No. MD998820, MD998814 and MD998812 or equivalents, press drive pinion into case until bearing part of snap ring contacts transmission case.

Fig. 15 Washer installation:

d. Install side washer so bent portion is in groove of transmission case.

Fig. 16 Staking locknut:

e. Crimp locknut (15) as shown in.
f. Install oil seal (12) with suitable seal installer and coat lip with multipurpose grease, then install the clutch housing with a coating of sealant on the installation surface.
g. Apply a coating of sealant to installation surface of gear shift lower case (10), then install.
h. Apply a coating of sealant to installation surface of transmission case, align shift rails with shift rail holes in transfer case adapter and temporarily install. After installing each shift jaw to each rail, install the transfer case adapter.
i. Install breather with identification mark toward rear of transmission.