Disassembly
FRONT HOUSING1. If necessary, temporarily reinstall shift lever assembly. Shift transmission into Neutral.
2. If lubricant was not drained out of transmission during removal, remove drain plug and drain lubricant into container at this time.
3. Inspect drain plug magnet for debris.
Fig. 9:
4. Remove backup light switch. Switch is located on passenger side of rear housing (Fig. 9).
Fig. 10:
5. If necessary, remove shift tower bolts and remove tower and lever assembly (Fig. 10).
Fig. 11:
6. Remove shift shaft lock bolt (Fig. 11). Bolt is located at top of front housing just forward of shift tower. Bolt is a shoulder bolt that secures the shift shaft bushing and lever.
7. Use Remover 8117 and suitable slide hammer to remove shift shaft detent plug.
Fig. 12:
8. Remove shift shaft detent plunger and spring (Fig. 12). Use pencil magnet to remove spring then plunger, if necessary.
Fig. 13:
9. Remove bolts attaching input shaft bearing retainer to front housing (Fig. 13).
10. Remove input shaft bearing retainer. Use pry tool to carefully lift retainer and
Fig. 14:
11. Remove bearing retainer from input shaft (Fig. 14).
Fig. 15:
12. Remove snap ring that secures input shaft in front bearing (Fig. 15).
Fig. 16:
13. Remove bolts that attach front housing to rear housing (Fig. 16). Three bolts at extreme rear of housing are actually for the output shaft bearing retainer. It is not necessary to remove all three bolts at this time. Leave at least one bolt in place until gear train is ready to be removed from case.
Fig. 17:
14. Separate front housing from rear housing (Fig. 17). Use plastic mallet to tap front housing off alignment dowels.
Fig. 18:
15. Remove and inspect input shaft bearing. Inspect countershaft front bearing race (Fig. 18).
Fig. 19:
16. Note position of input shaft, shift shaft and forks, and gear train components in housing (Fig. 19).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT
Fig. 20:
1. Using a hammer and suitable punch, drive out roll pin that secures shift bushing and lever to shift shaft (Fig. 20).
2. Position shift socket off to the side so that roll pin removal does not interfere with gears.
3. Using a hammer and suitable punch, drive out shift socket roll pin to release shift socket from shaft. Roll pin will fall to bottom of rear housing and is easily retrieved.
NOTE: Be sure to use the proper size punch to prevent damage to the shift shaft.
Fig. 21:
4. Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork, and 1-2 fork (Fig. 21).
Fig. 22:
5. Remove shift socket from rear housing (Fig. 22).
Fig. 23:
6. Remove lever and bushing (Fig. 23).
Fig. 24:
7. 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 (Fig. 24).
Fig. 25:
8. Remove the reverse idler shaft support bolt (front bolt) (Fig. 25).
9. Loosen rear reverse idler shaft bolt (rear bolt) (Fig. 25).
10. Remove reverse idler shaft support segment by sliding it straight out of housing.
11. Remove reverse idler shaft bolt (rear bolt).
Fig. 26:
12. Remove reverse idler shaft, idler gear, bearing, and thrust washer (Fig. 26).
GEAR TRAIN
Fig. 27:
1. Remove three bolts that attach output shaft bearing retainer to rear case (Fig. 27). Bolts are rear of shift tower opening.
Fig. 28:
2. Grab hold of mainshaft and countershaft and remove gear train from rear housing (Fig. 28).
3. Examine condition of output shaft rear bearing bore and idler shaft notch in rear housing. Replace housing if any of these components are damaged. Inspect countershaft rear bearing race and replace if necessary.
PRELIMINARY GEAR TRAIN
1. Remove 1-2 and fifth-reverse forks from synchro sleeves.
2. Separate countershaft from mainshaft.
3. Separate input shaft from output shaft.
4. Inspect input/output shaft pilot bearing, input shaft pocket bore, and 4th gear synchro ring. Replace if necessary
COUNTERSHAFT
1. Remove countershaft front and rear bearing with Puller 8356.
2. Remove rear bearing race (in rear housing) with Bearing Race Remover L-4454. Install new race with Race Driver C-4656 and Driver Handle C-4171.
3. Remove bearing shim cap from front housing (below input shaft bearing retainer). Remove shim. Drive race through and out of housing with Race Driver C-4656 and Driver Handle C-4171. Install new race and drive into housing from outside. Do not drive all the way into position. Tightening the shim cap will install the race to the proper position. Install shim and shim cap and torque the shim cap bolts to 28.5 Nm (21 ft. lbs.).
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. It is recommended that each synchronizer unit be removed as an assembly to avoid intermixing parts. It is also recommended that each synchro hub and sleeve be marked with a scriber or paint for correct assembly reference.
1. Remove snap ring that secures 3-4 synchro hub on output shaft.
2. Remove 3-4 synchro assembly, third gear synchro ring, and third gear with shop press and Remover Tool 1130. Position Tool 1130 between second and third gears.
Fig. 29:
3. Remove third gear needle bearing (Fig. 29).
4. Remove retaining ring that secures two-piece thrust washer on shaft.
Fig. 30:
5. Remove two-piece thrust washer (Fig. 30). Note position of washer locating lugs in shaft notches for installation reference.
Fig. 31:
6. Remove second gear and needle bearing (Fig. 31).
7. Remove 2nd-3rd gear thrust washer locating pin and store in a place where it can be found easily upon re-assembly,
8. Remove second gear synchro ring and synchro cone.
9. Remove 1-2 synchro hub snap ring.
Fig. 32:
10. Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Remover Tool 1130 (Fig. 32). Position Tool 1130 between first and reverse gears.
Fig. 33:
11. Remove first gear needle bearing (Fig. 33).
Fig. 34:
12. Remove output shaft bearing snap ring (Fig. 34).
13. Remove output shaft bearing from shaft with shop press and remover tool 1130. Position Tool 1130 between bearing and 5th gear.
Fig. 35:
14. Remove fifth gear (Fig. 35).
Fig. 36:
15. Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (Fig. 36).
Fig. 37:
16. Remove fifth-reverse synchro hub snap ring (Fig. 37).
Fig. 38:
17. Remove fifth-reverse synchro hub and sleeve with shop press (Fig. 38).
Fig. 39:
18. Remove reverse gear and needle bearing (Fig. 39).