Case

Special Tools:

Disassembly
1. Remove the three screws and the release bearing guide tube.

2. Remove the oil seal.
3. Use the Slide Hammer and Bearing Cup Puller, remove the input shaft bearing outer race.

4. NOTE: The oil baffle will be destroyed when the race is removed.

Use the Slide Hammer and Bearing Cup Puller to remove the oil baffle, input bearing front shims and the input bearing outer race.

5. Use the Slide Hammer and Bearing Cup Puller to remove the front bearing outer race.

6. Remove the case plugs.

7. Remove the 5th-reverse interlock plate roll pins.

8. Use Slide Hammer and Blind Hole Puller to remove the central shift rail needle bearing.

Assembly

1. Install the 5th-reverse interlock plate roll pins.
^ Install the large pin until it bottoms out (will stick out approximately 8 mm (0.315 inch).

^ NOTE: Do not allow the small pin to bottom out.

Install the small pin (pin will stick out 4 - 5 mm [0.158 - 0.197 inch]).
2. Install the central shift rail needle bearing.
^ Using a Heat Gun, heat the bearing bore area to 160°C (320°F).
^ Use Drive Handle and Needle Bearing Replacer to install the needle bearing until its flush with the surface of the bore.

3. Install new seal rings and case plugs.

4. CAUTION: If the countershaft cluster gear, input shaft, main shaft or one or more tapered roller bearings has been replaced, it is mandatory that the tapered roller bearings be adjusted to obtain a preload of 0.02 to 0.11 mm (0.00079 to 0.00434 inch).

Use the Driver Handle and Front Seal Replacer to install the oil seal until it seats against its stop.

5. Install the output bearing outer race.
1 Use a heat gun to heat the bearing bore to 160°C (320°F).
2 Position the oil baffle and front shim in the bearing bore.
3 Use Drive Handle and Main Shaft Bearing Cup Replacer to install the output shaft bearing until it seats against the stop in the case.

6. Install the front bearing outer race.
^ Use a Heat Gun to heat the bearing bore to 160°C (320°F).
^ Use Driver Handle and Front Bearing Cup Replacer to install the bearing until it seats against the stop in the case.