Disassembly

Special Tools:

1. WARNING: Wear protective eye wear whenever using compressed air.

Clean the transmission exterior with solvent, and dry with compressed air.

2. WARNING: Wear protective eye wear whenever using compressed air.

Clean all parts removed with solvent, and dry with compressed air.

3. Remove the clutch release lever and the clutch release hub and bearing.

4. Using the special tools, remove the pinion flange on 2-wheel drive vehicles

5. Remove the eight bolts and the shift housing.

6. CAUTION: To prevent damage, do not heat the shift housing higher than 150° C (300° F).

Note: Inspect the shift detent plunger for wear or damage. Check plunger operation.

Using the Heat Gun, remove the shift detent plunger.
^ Using a hammer and punch, tap the shift detent plunger from the housing.

7. Remove the fifth and reverse gear interlock and the interlock spring.

8. Using the special tool, secure the transmission to a suitable workbench.
^ Position the transmission with the input shaft facing upward.

9. Remove the transmission mount.

10. WARNING: Shift rail detent plug is under spring pressure. Always wear protective eyeglasses when performing this procedure to make sure that shift rail detent plug does not strike eyes when it is forced out by spring pressure.

Note: Use a 1/8 inch center punch to create a pilot hole in the plug before installing the tool. Using the Jet Plug Remover to make the pilot hole will damage the tool.

Using the Jet Plug Remover, remove the shift rail detent plugs and springs. Discard the detent plugs.
^ Lightly thread in the Jet Plug Remover so as not to damage the springs.

11. Remove the upper reverse idler gear bolt, only loosen the lower reverse idler gear bolt.

12. Remove the 17 bolts.

13. Note: The dowel pins do not have to be removed.

Using a hammer and punch, tap the two dowel pins down until they are past the main case.

14. CAUTION: Do not use a pry bar or a screwdriver to force the main case and extension housing apart. This could damage the mating surfaces and cause leaks.

Carefully lift the main case off the extension housing.
^ Using a soft-faced hammer, tap the main case lightly to break the gasket seal.
^ It may be necessary to push the main shift rail driver inwards to prevent it from hanging up on the case as it is being removed. Use care to make sure that the main shift rail is not lifted off with the case.

15. Remove the main shift rail and the main shift rail driver.

16. Remove the reverse idler gear assembly.
1. Remove the reverse idler gear bolt.
2. Remove the reverse idler shaft.
3. Remove the reverse idler gear and the two reverse idler gear bearings.
^ Inspect the idler shaft, gear and bearings for wear or damage. Install new components, as necessary.

17. Remove one bolt from the shift interlock plate.

18. Position the special tools onto the gear assembly. Attach the tools to the gear assembly with a cargo strap.

19. Note: An assistant will be needed to remove the gear assembly from the bench fixture.

Firmly hold the gear assembly, release the holding fixture from the bench fixture, then remove the transmission. Place the gear assembly on a workbench.

20. Remove the remaining bolts from the shift interlock plate.

21. Separate the extension housing from the gear assembly.

22. Note: The mainshaft rear spacer is used on 2-wheel drive vehicles only.

Remove the mainshaft rear spacer.

23. Remove the shift interlock plate.
^ Remove the cargo strap from around the shift rails and gear assembly.

24. Remove the shift rail assembly and the Shift Rod Support.
^ Inspect the shift rails and shift forks for wear or damage. Disassemble and install new components as necessary.

25. Inspect the shift fork pads and centers for wear or damage. Install new shift forks as necessary.

26. Remove the countershaft from the Gear Pack Holding Fixture and set it aside.

27. Note: Secure the Axle Bearing Plate in a vise.

Remove the mainshaft from the Gear Pack Holding Fixture and place in the Axle Bearing Seal Plate.