Shift Shaft, Shift Forks and Reverse Idler Segment Removal
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT REMOVAL1. Place shop towel over shaft lever and bushing to contain lever detent ball and spring.
Removing Shift Shaft Lever Detent Ball And Spring:
2. Rotate lever and bushing upward out of shift forks and catch ball and spring as they exit shaft lever.
3. Unseat roll pin that secures shift socket to shift shaft with Special Tool 6858 as follows:
Unseating Shift Socket Roll Pi With Tool 6858:
(a)/9GPosition Tool 6858 on shift socket. Then center tool over roll pin. Be sure tool legs are firmly seated on shift socket.
b. Tilt socket toward side of case. This places roll pin at slight angle to avoid trapping pin between gear teeth.
c. Tighten tool punch to press roll pin downward and out of shift socket. Roll pin does not have to come completely out of shift shaft; it only has to clear shift socket. Be careful not to drive roll pin out of shaft far enough to jam into the geartrain.
Removing Shift Shaft Lever And Bushing Roll Pin:
4. Drive out roll pin that secures shift bushing and lever to shift shaft.
Shift Shaft Removal:
5. Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork, and 1-2 fork.
Shift Socket And Roll Pin:
6. Remove shift socket from rear housing.
Removing Shift Shaft Lever And Bushing:
7. Remove lever and bushing.
Removing 3-4 Shift Fork:
8. Remove 3-4 fork. Rotate 3-4 fork around synchro sleeve until fork clears shift arms on 1-2 and fifth-reverse forks. Then remove 3-4 fork.
9. Remove the front reverse idler shaft bolt.
10. Loosen rear reverse idler shaft bolt.
11. Remove reverse idler shaft support segment by sliding it straight out of housing.
12. Support geartrain and rear housing on Assembly Fixture Tool 6747 as follows:
a. Adjust height of reverse idler pedestal rod until the reverse idle shaft bottoms in Cup 8115.
b. Position Adapters 6747-1A and 6747-2A on Assembly Fixture 6747.
Installing Assembly Fixture On Geartrain:
c. Slide fixture tool onto input shaft, countershaft and idler gear.
Geartrain And Housing Mounted On Fixture Tool:
d. Stand geartrain and rear housing upright on fixture. Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position.
13. Remove rear bolt holding reverse idler shaft in housing.