Overhaul (Disassembly)

Transmission





Special Tool(s)

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. Set the transmission on a work bench.





4. Remove the case cover.
1 Remove the case cover bolts.
2 Separate the case cover from the transmission.





5. Remove the extension housing.
1 Remove the 9 extension housing bolts.
2 Separate the extension housing from the transmission.





6. Using the special tool, remove the extension housing seal.





7. Remove the VSS tone ring.
1 Remove the tone ring retaining ring.
2 Remove the tone ring and the locating ball.





8. Slide the 1st/2nd and 3rd/4th synchronizer sleeves forward to lock the transmission into 1st and 3rd gears.





9. NOTE: Release the stake mark on the nut.

Remove and discard the countershaft locknut.





10. Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.





11. NOTE: Release the stake mark on the nut.

Using the transmission locknut socket, remove the output shaft rear bearing locknut.





12. Remove the reverse idler shaft bolt.





13. Remove the reverse idler gear and bushing.





14. Use the special tools to remove the output shaft bearing.





15. Remove the output shaft reverse gear and bushing.





16. Remove the output shaft spacer.





17. Remove the countershaft reverse gear, the 2 countershaft reverse gear bearings and the reverse synchronizer blocking ring.





18. Remove the reverse gear thrust washer.





19. Remove the countershaft split washer.





20. Remove the reverse gear shift rail bolt.





21. Remove the 5th reverse synchronizer, the gear shifter fork and the reverse gear shift rail as an assembly.





22. Remove the countershaft 5th gear synchronizer blocking ring.





23. Remove the countershaft 5th speed gear.





24. Remove the countershaft 5th speed gear split bearing, the inner race, then the locating ball.





25. Remove the 5th and reverse shift lever retaining ring and the 5th and reverse shift lever.





26. Remove the lock plate bolt, then slide the shaft out of case.





27. Remove the output shaft 5th speed gear.





28. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.





29. Remove the rear bearing retainer bolts and the rear bearing retainer, then remove the rear countershaft bearing.





30. Remove the 6 front bearing retainer bolts.





31. Install special tool into the slave cylinder bolt locations. Alternately tighten bolts until the front bearing retainer can be removed by hand. Remove the front bearing retainer.
32. Remove the front countershaft bearing.





33. Remove the fluid baffle, the fluid baffle shim and the countershaft bearing shim.





34. Remove the fluid passage bolt.





35. Remove the fluid passage.





36. Remove the input shaft front bearing race.





37. Remove the output shaft center bearing race.





38. Remove the center countershaft bearing.





39. Separate the input shaft and the output shaft.





40. Remove the output shaft.
^ Move the countershaft down to gain room then remove the output shaft.





41. Remove the input shaft.





42. Remove the countershaft.





43. Inspect the countershaft for damage.