Disassembly

DISASSEMBLY

Transmission

Special Tool(s):

1. WARNING: Wear protective EYEWEAR whenever using compressed air.

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

2. WARNING: Wear protective EYEWEAR 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 10 shift control housing bolts.
2 Separate the shift control housing from the transmission.





5. Remove the shift control housing seal.





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





7. Remove the shipping seal.





8. Remove the tone ring retaining ring and the vehicle speed sensor (VSS) tone ring.





9. Remove the locating ball.





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





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

Remove and discard the countershaft locknut.





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





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

Using the special tool, remove the output shaft rear bearing locknut.





14. Remove the reverse idler shaft bolt.





15. Remove the reverse idler gear.





16. Using the special tools, remove the output shaft bearing.





17. Remove the output shaft reverse gear and bushing.





18. Remove the output shaft spacer.





19. Remove the following components:
^ Countershaft reverse gear
^ Two countershaft reverse gear bearings
^ Reverse synchronizer blocking ring
^ Reverse gear thrust washer





20. Remove the countershaft split washer.





21. Remove the reverse gear shift rail bolt.





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





23. Separate the gear shifter fork from the 5th/reverse synchronizer.





24. Remove the countershaft 5th gear synchronizer blocking ring and 5th gear.





25. Remove the following components:
^ Countershaft 5th gear split bearing
^ Inner race
^ Locating ball





26. Remove the 5th/reverse shift lever retaining ring, the washer and the 5th/reverse shift lever.





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





28. Remove the output shaft 5th speed gear.





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





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





31. Remove the 6 front bearing retainer bolts.
^ Install the special tool into the slave cylinder bolt locations. Remove the front bearing retainer.
^ Alternately tighten the bolts until the front bearing retainer can be removed by hand.
^ Remove the front bearing retainer.





32. Remove the fluid baffle shim.





33. Remove the front bearing retainer seal.
^ Discard the seal.





34. Remove the fluid baffle.





35. Remove the front countershaft bearing.





36. Remove the fluid passage bolt.





37. Remove the fluid passage.





38. Remove the input shaft front bearing race.





39. Remove the output shaft center bearing race and the center countershaft bearing.





40. Separate the input shaft from the output shaft.
^ Move the countershaft rearward and rotate the input shaft to position the flat section downward.





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





42. Remove the input shaft.





43. Remove the countershaft.