Case

Case





Special Tool(s)

Disassembly





1. Remove the guide tube.
^ Inspect the guide tube for wear or damage. Install a new guide tube as necessary.





2. Remove and discard the input shaft oil seal.





3. Using the special tools, remove the input shaft bearing cup, the oil dam and the shims.
^ Using a hammer and punch, tap down two areas on the oil dam, 180 degrees apart, to insert the puller under the cup.
^ Inspect the bearing cup for wear or damage. Install a new cup as necessary.
^ If a new bearing was installed on the input shaft, install a new cup.





4. Use the special tools, remove the countershaft front bearing cup.
^ Inspect the bearing cup for wear or damage. Install a new cup as necessary.
^ If a new bearing was installed on the countershaft, install a new cup.





5. Remove the case plug and discard the seal.
6. Remove the reverse lamp switch and discard the seal.





7. Remove the Power Take-Off (PTO) covers.





8. Using the special tools, remove and discard the shift rail bearing.

9. NOTE: Use care when cleaning the mating surfaces. Nicks and gouges can prevent sealing and cause leaks. Clean the mating surfaces with an oil stone.

Clean the mating surface of the case.

Assembly

NOTE: A preload measurement must be taken after transmission disassembly.





1. NOTE: If installing a new case, new interlock plate toll pins must be installed.

Install the interlock plate roll pins.
^ Install the large pin until it bottoms out (will stick out approximately 8 mm [0.32 inch]).

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

Install the small pin (will stick out 4 - 5 mm [0.158 - 0.197 inch]).





2. Using the special tools, install anew shift rail bearing.
^ Use the Heat Gun to heat the bearing bore to 150°C (300°F).
^ Bearing should be flush with the surface of the bore.





3. Install the case plug with a new seal.





4. Using the special tools, install the input shaft bearing cup.
^ Do not install the oil trough, shim or oil dam at this time. The bearing preload adjustment procedure will determine the thickness of the shim to be installed.
^ Use the Heat Gun to heat the bearing bore to 150°C (300°F).





5. Using the special tools, install the countershaft front bearing cup.
^ Do not install the shim at this time. The bearing preload adjustment procedure will determine the thickness of the shim to be installed.
^ Use the Heat Gun to heat the bearing bore to 150°C (300°F).

6. Install a new input shaft oil seal and the guide tube after the bearing preload is completed.