Disassembly

DISASSEMBLY
FRONT HOUSING
1. Shift transmission into Neutral.
2. If lubricant was not drained out of transmission during removal, remove drain plug and drain lubricant.
3. Inspect drain plug magnet for debris.





4. Remove backup light switch located on passenger side of rear housing (Fig. 3).





5. Remove shift tower bolts and remove tower and lever assembly (Fig. 4).





6. Remove shift shaft lock bolt (Fig. 5). 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. Remove bolts attaching input shaft bearing retainer to front housing and remove retainer.





NOTE: Use pry tool to carefully lift retainer and break sealer bead (Fig. 6).





8. Remove bearing retainer from input shaft (Fig. 7).





9. Remove snap ring that secures input shaft in front bearing (Fig. 8).
10. Remove shift shaft detent plug with Remover 8117A. Attach fingers of the remover to the detent plug and push the cup down till it contacts the trans. Then tighten the nut till it pulls the plug from the case.
11. Remove shift shaft detent plunger and spring with a pencil magnet.





12. Remove bolts that attach front housing to rear housing (Fig. 9). 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 geartrain is ready to be removed from case.





13. Separate front housing from rear housing (Fig. 10). Use plastic hammer to tap front housing off alignment dowels.





14. Remove and inspect input shaft bearing. Inspect countershaft front bearing race (Fig. 11).





15. Note position of input shaft, shift shaft and forks, and geartrain components in housing (Fig. 12).

SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT





1. Unseat shift socket roll pin with Remover 6858. Position remover on shift shaft and center tool over the roll pin. Verify tool legs are firmly seated on the shift socket (Fig. 13).
2. Tilt socket toward the side of the case to avoid trapping the pin between the gear teeth.
3. Tighten remover to press the roll pin downward and out of the shift socket (Fig. 13).

NOTE: Roll pin does not have to be completely removed, the pin must only be clear of the shift shaft. Be careful not to push the pin into the geartrain.





4. Drive out shift bushing and lever roll pint with a hammer and punch (Fig. 14).

NOTE: Use proper size punch to avoid bending the shift shaft.





5. Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork and 1-2 fork (Fig. 15).





6. Remove shift socket from rear housing (Fig. 16).





7. Remove lever and bushing (Fig. 17).





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 (Fig. 18).





9. Remove the reverse idler shaft support bolt (front bolt) (Fig. 19).
10. Loosen rear reverse idler shaft bolt (rear bolt) (Fig. 19).
11. Remove reverse idler shaft support segment by sliding it straight out of housing.
12. Support geartrain and rear housing on Fixture 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 6747-2B on Fixture 6747.





c. Slide fixture tool onto input shaft, counter- shaft and idler gear (Fig. 20).





d. Stand geartrain and rear housing upright on fixture (Fig. 21). 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.

REAR HOUSING - 2WD





1. On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 22). Bolts are rear of shift tower opening.





2. Unseat output shaft bearing from bearing bore in rear housing. With a plastic/rawhide hammer tap rear housing upward and off output shaft bearing (Fig. 23).





3. Lift rear housing up and off geartrain (Fig. 24).





4. Remove countershaft rear bearing from countershaft (Fig. 25).
5. Examine condition of bearing bore and idler shaft notch in rear housing. Replace housing if any of these components are damaged.

REAR ADAPTER HOUSING - 4WD








1. Locate dimples in face of rear seal (Fig. 26). With a slide hammer mounted screw remove seal by inserting screw into seal at dimple locations (Fig. 27).





2. Remove rear bearing snap ring from output shaft with snap ring pliers (Fig. 28).





3. Lift rear adapter housing upward and off geartrain (Fig. 29).





4. Remove bearing retainer bolts and remove rear bearing retainer and rear bearing (Fig. 30). Use hammer handle to push or tap bearing out of housing if needed.
5. Examine condition of bearing bore, countershaft rear bearing race and idler shaft notch in rear housing. Replace housing if race, bore or notch are worn or damaged.

GEARTRAIN FROM FIXTURE
1. Remove reverse idler gear assembly from assembly fixture cup.
2. Remove 1-2 and fifth-reverse forks from synchro sleeves.
3. Slide countershaft out of fixture tool.
4. Remove output shaft bearing retainer from rear surface of fifth gear (retainer will drop onto gear after bolts are removed).
5. Lift and remove output shaft and gears off input shaft.
6. Lift and remove input shaft, pilot bearing and fourth gear synchro ring from assembly fixture tool.

OUTPUT SHAFT

NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. Remove each synchronizer unit as an assembly to avoid intermixing parts. Mark each synchro hub and sleeve 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 Bearing Splitter 1130.6Position splitter between second and third gears.





3. Remove third gear needle bearing (Fig. 31).





4. Remove retaining ring that secures two-piece thrust washer on shaft with a small pry tool (Fig. 32).





5. Remove two-piece thrust washer (Fig. 33). Note position of washer locating lugs in shaft notches for installation reference.





6. Remove second gear and needle bearing (Fig. 34).





7. Remove second gear synchro ring, synchro friction cone, and synchro cone (Fig. 35).
8. Remove interm ring.
9. Remove 1-2 synchro hub snap ring.





10. Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Bearing Splitter 1130 (Fig. 36). Position splitter between first and reverse gears.





11. Remove first gear needle bearing (Fig. 37).





12. Remove output shaft bearing snap ring (Fig. 38).
13. On 2-wheel drive models, remove output shaft bearing.





14. Remove fifth gear (Fig. 39).





15. Remove fifth gear needle bearing, spreading bearing apart just enough to clear shoulder on output shaft (Fig. 40).





16. Remove fifth-reverse synchro hub snap ring (Fig. 41).





17. Remove fifth-reverse synchro hub and sleeve with shop press (Fig. 42).





18. Remove reverse gear and needle bearing (Fig. 43).

REVERSE IDLER





1. Remove idler gear snap rings (Fig. 44).
2. Remove thrust washer, wave washer, thrust plate and idler gear from shaft.
3. Remove idler gear needle bearing from shaft.