Disassembly

Transmission





1. Remove the transmission. For additional information, refer to Transmission - Rear Wheel Drive (RWD) Removal - Transmission or Transmission - Four Wheel Drive (4WD) Removal - Transmission.

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

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

4. Set the transmission on a work bench.

5. Remove the 10 shift control housing bolts and the shift control housing.





6. Remove the shift control housing gasket.





7. Remove the 8 bolts and the extension housing.





8. Using a suitable tool, carefully remove the extension housing seal.





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





10. Remove the tone wheel snap ring, the tone ring and the locating ball.





11. Using the Transmission Shaft Locknut Socket, remove and discard the output shaft rear bearing locknut.





12. Remove and discard the countershaft locknut.





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





14. Remove the reverse idler shaft bolt, then remove the reverse idler gear and bushing.





15. Using the Mainshaft Bearing Remover, Bearing Tube Remover/Installer and the Bearing Tube Removal Screw, remove the output shaft rear bearing.





16. Remove the output shaft reverse gear.





17. Remove the spacer.





18. Remove the countershaft reverse gear, the 2 countershaft reverse gear needle bearings, the reverse synchronizer blocking ring and the thrust washer.





19. Remove the countershaft split washer.





20. Remove the 5th/reverse gear shift rail bolt.





21. Remove the following:
- Countershaft 5th gear synchronizer blocking ring

- 5th/reverse synchronizer

- Gear shifter fork

- Reverse gear shift rail

- Countershaft 5th gear split bearing and the race

- Countershaft 5th gear









22. Remove the 5th/reverse shift lever bolt and the nut, then remove the plate.





23. Remove the snap ring and washer, then slide the 5th/reverse shift lever and shaft assembly from the case.





24. Remove the locking ball.

25. Remove the output shaft 5th gear.





26. Remove the 6 rear bearing retainer bolts and the rear bearing retainer.





27. Remove the clutch slave cylinder. For additional information, refer to Clutch, M/T.

28. Remove the 6 front bearing retainer bolts.





29. Install the Front Cover Remover bolts into the clutch slave cylinder bolt locations. Alternately tighten the bolts until the front bearing retainer can be removed by hand.





30. Remove the fluid baffle, the input bearing shim and the countershaft bearing shim.





31. Remove the front oil passage bolt.





32. Remove the front oil passage.





33. Remove the input shaft front bearing cup and the countershaft bearing.





34. Remove the output shaft center bearing cup and the countershaft bearing.





35. Separate the input shaft from the output shaft.





36. Remove the output shaft.





37. Remove the input shaft and bearing.





38. Remove the countershaft cluster gear.





39. Inspect the countershaft for wear or damage. Install a new countershaft as necessary.