NV5600 Transmission
PRELIMINARYNOTE: The use of Fixture 8241 for moving and handling the NV5600 is required. The fixture supports the transmission at the center of gravity in order to ease mounting the transmission into the build fixture.
1. Using Fixture 8241, mount the transmission into the Build Fixture 8230.
2. Rotate the transmission to the horizontal position, if necessary.
Fig. 19:
Fig. 20:
3. Remove the shift tower (Fig. 19) and isolator plate (Fig. 20).
Fig. 21:
4. Remove the primary shift rail detent plug (Fig. 21).
Fig. 22:
5. Remove the primary shift rail detent spring (Fig. 22).
Fig. 23:
6. Remove the primary shift rail detent plunger (Fig. 23).
Fig. 24:
7. Remove the bolts (10) (Fig. 24) inside the clutch housing, holding the clutch housing to the transmission gear case.
Fig. 25:
8. Remove the shift rail blocker bolt (Fig. 25) from the side of the transmission gear case.
EXTENSION/ADAPTER HOUSING
1. Remove the bolts holding the extension/adapter housing onto the transmission gear case.
Fig. 26:
2. Using Puller 8244, remove the extension/adapter housing (Fig. 26) from the transmission gear case.
NOTE: It may be necessary to straighten the housing during removal due to the tendency for the reverse idler shaft to bind into one side of the housing.
Fig. 27:
3. Remove the crossover detent plug from the extension/adapter housing (Fig. 27).
4. Remove the crossover detent spring from the extension/adapter housing.
5. Remove the crossover detent plunger from the extension/adapter housing
Fig. 28:
6. Remove the bolt and washer holding the crossover cam to the extension/adapter housing (Fig. 28).
7. Remove the crossover cam from the extension/adapter housing.
8. Remove the back-up lamp switch and gasket from the extension/adapter housing.
Fig. 29:
9. Use Remover L-4518 to remove the countershaft rear bearing race from the extension/adapter housing (Fig. 29).
Fig. 30:
NOTE: Be sure to remove and tag all countershaft preload shims from between the bearing race and the housing (Fig. 30).
10. Use Remover 8240 to remove the crossover cam bushing from the extension/adapter housing.
11. On 4X2 vehicles, remove extension housing seal with a suitable pry tool or a slide hammer mounted screw.
12. On 4X4 vehicles, use a suitable pry tool, or a slide hammer mounted screw, to remove the adapter housing seal.
REVERSE GEAR
Fig. 31:
1. Remove the crossover cam rollers and pin (Fig. 31).
2. Remove the reverse idler thrust washer from the reverse idler.
Fig. 32:
3. Remove the reverse idler and reverse countershaft gears together (Fig. 32).
4. Remove the reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer from the idler gear shaft.
Fig. 33:
5. Use Puller C-293-PA and Adapters C-293-52 to remove the reverse countershaft rear bearing from the countershaft reverse gear assembly (Fig. 33).
Fig. 34:
6. Use a suitable bearing splitter and shop press to separate the countershaft reverse gear and sleeve (Fig. 34).
Fig. 35:
7. Using Wrench 8226 on the output shaft nut and Socket 6993, or 6984, to hold the output shaft, loosen the output shaft nut (Fig. 35). Remove and discard the output shaft nut from the output shaft.
NOTE: The high torque can make the output shaft nut difficult to remove. If necessary, strike the flat side area of Wrench 8226 with a hammer to break the nut loose.
Fig. 36:
8. Remove the output shaft ball bearing assembly and reverse thrust washer from the output shaft (Fig. 36).
Fig. 37:
9. Remove reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring, and reverse gear bearing (Fig. 37).
Fig. 38:
10. Remove the reverse gear bearing sleeve from the output shaft (Fig. 38).
NOTE: It may be necessary to heat the sleeve slightly with a heat gun. Do not use a torch to heat the sleeve or damage to the output shaft may occur.
11. Using a suitable punch and hammer, remove the roll-pin securing the reverse shift fork to the reverse shift rail. The correct size punch is 6 mm (7/32 inch).
Fig. 39:
12. Remove the reverse shift fork and synchronizer as an assembly from the reverse shift rail and the output shaft (Fig. 39).
TRANSMISSION GEAR CASE
1. Remove the remaining bolts holding the transmission gear case to the clutch housing.
2. Using a suitable punch and hammer, remove the shift socket roll pin. The correct size punch is 6 mm (7/32 inch).
3. Install Fixture 8232 to the transmission gear case.
Fig. 40:
4. Attach an engine crane, or equivalent, to Fixture 8232 and remove the transmission gear case from the clutch housing (Fig. 40).
5. Using a suitable brass drift and hammer, remove the rear output shaft and countershaft bearing races from the transmission gear case.
GEARTRAIN
Fig. 42:
1. Remove the bolts holding the 5-6 crossover bracket to the clutch housing (Fig. 42).
Fig. 41:
2. Attach Fixture 8232 to the output shaft and countershaft (Fig. 41).
3. Attach an engine crane, or equivalent, to Fixture 8232 and raise the geartrain approximately 1/4 inch from the clutch housing.
4. Remove the 5-6 crossover bracket from the clutch housing.
5. Lower the geartrain back into the clutch housing.
Fig. 43:
6. Install Holding Tool 8242 (Fig. 43) onto the 5-6 synchro and tighten the screw to hold the 5-6 synchro together during the removal operation.
NOTE: Pay close attention to the order of the shift fork arms at 1he primary shift rail when they are in the Neutral position.
7. Raise the geartrain and shift rails until all the shift rails clear the clutch housing.
Fig. 44:
8. Remove the shift rails from the rest of the geartrain (Fig. 44).
9. Raise the geartrain until the input shaft is clear of the clutch housing.
Fig. 45:
10. Remove the geartrain from the clutch housing and install the geartrain into Support Stand 8246 (Fig. 45).
11. Remove Fixture 8232 from the output shaft and the countershaft.
12. Separate the countershaft; from the output shaft.
13. Separate the output shaft from the input shaft. Be sure to hold the 5-6 synchro together while removing the output shaft to prevent the synchro sleeve from being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
1. Remove the snap-ring holding the front countershaft bearing onto the countershaft.
Fig. 46:
2. Use Sleeve 6444-8, Adapters 6451, and Puller Rods 6444-4 with the remainder of Puller 6444 to remove the front countershaft bearing (Fig. 46).
Fig. 47:
3. Use Sleeve 6444-8, Adapters 6447, Puller Rods 6444-4, and suitable press button with the remainder of Puller 6444 to remove the rear countershaft bearing (Fig. 47).
OUTPUT SHAFT BEARINGS
1. Remove the snap-ring holding the pocket bearing onto the output shaft.
Fig. 48:
2. Use Sleeve 6444-8, Adapters 8234, and Puller Rods 6444-4 with the remainder of Puller 6444 to remove the pocket bearing from the output shaft (Fig. 48).
3. Remove the snap-ring holding the rear output shaft bearing onto the output shaft.
4. Use Sleeve 6444-8, Adapters 8271, and Puller Rods 6444-3, for 4X2 vehicles, or Puller Rods 6444-4, for 4X4 vehicles, with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft.
5. Remove the rear output shaft thrust washer from the output shaft.
INPUT SHAFT
Fig. 49:
1. Remove the fifth gear blocker ring from the input shaft (Fig. 49).
Fig. 50:
2. Remove the fifth gear friction cone from the input shaft (Fig. 50).
Fig. 51:
3. Use Puller L-4518 to remove the output shaft pocket bearing race from the input shaft (Fig. 51).
Fig. 52:
4. Use Sleeve 6444-8, Adapters 8243, and Puller Rods 6444-6 with the remainder of Puller 6444 to remove the input shaft bearing and oil guide from the input shaft (Fig. 52).
OUTPUT SHAFT
NOTE: Not all of the output shaft gear and synchro components are a one-way fit. Some gear and synchro components can be installed backwards. To avoid reassembly problems, mark the gears, clutch gears, synchro hubs, and sleeves for reference during teardown. Use paint or a scriber for marking purposes. Then stack the geartrain parts in order of removal. This practice will help avoid incorrect assembly.
1. Remove first gear from the output shaft.
Fig. 53:
2. Remove the first gear bearing from the output shaft (Fig. 53).
Fig. 54:
3. Remove the first gear blocker rings (2) and cones from the 1-2 synchro assembly (Fig. 54).
4. Install the remainder of the output shaft into Fixture 8227 with press blocks under second gear.
5. Install shaft and Fixture assembly into a suitable shop press.
6. Using the shop press, remove second gear, 1-2 synchro assembly, and first gear bearing sleeve from the output shaft.
Fig. 55:
7. Remove the second gear bearing from the output shaft.
8. Reverse the output shaft in the Fixture 8227 with press blocks positioned under the 5-6 synchro assembly.
9. Using the shop press, remove the 5-6 synchro assembly from the output shaft.
Fig. 56:
10. Remove sixth gear and the sixth gear bearing from the output shaft (Fig. 56).
COUNTERSHAFT
1. Install the countershaft into Fixture 8227 with press blocks located under the fifth countershaft gear.
2. Place the complete assembly into a suitable shop press.
Fig. 57:
3. Use Guide 8235 on end of countershaft and remove the countershaft, fifth gear from the countershaft (Fig. 57).
4. Place countershaft, in Fixture 8227 with press blocks placed under the sixth countershaft gear.
Fig. 58:
5. Use Guide 8235 on end of countershaft and remove the countershaft, sixth gear from the countershaft (Fig. 58).
6. Remove the countershaft from the press and Fixture 8227.
7. Remove the fourth countershaft gear from the countershaft.
8. Remove the fourth countershaft gear friction cone from the countershaft.
9. Remove the fourth countershaft gear blocker ring from the countershaft.
Fig. 59:
10. Remove the fourth countershaft gear bearing from the countershaft (Fig. 59).
11. Install the countershaft into Fixture 8227 with press blocks located under the third countershaft gear
Fig. 60:
12. Place the complete assembly into a suitable shop press and remove the third countershaft gear, 3-4 synchro, and fourth countershaft gear bearing sleeve from the countershaft (Fig. 60).
13. Remove the countershaft from the press and Fixture 8227.
Fig. 61:
14. Remove the third countershaft gear bearing from the countershaft (Fig. 61).
15. The 2-3 thrust washer should not normally need to be removed from the countershaft. If necessary, remove the 2-3 thrust washer from the countershaft using a suitable punch and hammer. Alternate striking the 2-3 thrust washer from diagonally opposite positions and "walk" it off the shaft.
CLUTCH HOUSING
1. Remove the bolts holding the input shaft retainer onto the clutch housing.
Fig. 62:
2. Separate the input shaft retainer from the clutch housing (Fig. 62).
Fig. 63:
3. Remove the countershaft oil guide from the countershaft front bearing bore in the clutch housing (Fig. 63).
Fig. 64:
4. Using Remover 6061-1 and Handle C-4171, remove the countershaft front bearing race, endplay shims, and spacer from the clutch housing (Fig. 64).
5. Using Remover/Installer 8237 and Handle C-4171, remove the input shaft bearing race.
Fig. 65:
6. Remove the input shaft oil guide and retainer seal (Fig. 65).