Disassembly

Special Service Tool(s) Required:

1. Attach transmission adapter to flywheel housing (6392) as shown. Mount transmission in Bench Mounted Holding Fixture T57L-500-B.





2. Using a 3/8-inch drive ratchet and extension, remove case plug (7A010) located on lower RH side of transmission extension housing (7A039). Drain fluid.





3. Using 22mm wrench, remove backup lamp switch (15520).





4. CAUTION: Do not attempt to remove the gearshift offset lever while the extension housing is bolted in place. A lug, located on the bottom of the gearshift offset lever, meshes with the detent plate preventing enough rearward movement of the gearshift offset lever to allow removal.

- Position gearshift lever (7210) in NEUTRAL position. Using a 13 mm socket, remove four retaining bolts.





5. Using a suitable pry bar, break shift turret cover-to-extension housing seal by prying carefully between extension housing and cover. Remove turret cover.





6. Using a 5 mm (3/16-inch) pin punch and hammer, drive split pin through gearshift offset lever as far as possible.





7. Note location of aluminum identification tag. Remove eleven extension housing retaining bolts.





8. Using a suitable pry bar, break extension housing-to-case seal by prying carefully between extension housing and case (7005).





9. Remove extension housing and gearshift offset lever as an assembly by sliding rearward away from case.





10. Remove gearshift offset lever, split pin, detent spring and detent ball from extension housing detent plate.





11. Rotate transmission to upright position. Remove full fill seal from output shaft.





12. Remove speedometer drive gear rear retaining ring from output shaft.





13. Remove speedometer drive gear (17285) from output shaft.





14. Remove speedometer drive gear front retaining ring from output shaft.





15. Remove output shaft bearing rear retaining ring.





16. Using Remover/Replacer Tube T75L-7025-B, Bearing Puller T77J-7025-H and Puller Ring T77J-7025-J, carefully remove output shaft support bearing and discard.





17. Remove output shaft bearing front retaining ring.





18. Remove selectable thrust washer from rear of reverse driven gear.





19. Remove reverse driven gear and needle bearing from output shaft.





20. Remove reverse driven gear bearing thrust washer from output shaft.





21. Remove retaining ring from behind reverse driven gear hub on output shaft.





22. Remove reverse drive gear retaining ring from countershaft cluster gear (7113).





23. Remove reverse drive gear spacer from countershaft cluster gear.





24. Remove reverse drive gear from countershaft cluster gear.





25.NOTE: Identify blocker ring for reassembly.

- Remove reverse drive gear blocker ring


26. Using 5 mm (3/16-inch) punch, remove split pin from fifth/reverse gear shifter fork (7230).






27. NOTE: Use caution to prevent binding or cocking of assembly when removing.

Simultaneously remove reverse synchronizer sleeve from output shaft, fifth/reverse gear shifter fork from shift rail and fifth/reverse synchronizer sleeve from fifth/reverse synchronizer hub on countershaft cluster gear.






28. Remove reverse synchronizer hub from output shaft.





29. Remove retaining ring from rear of fifth/reverse synchronizer hub on countershaft cluster gear.







30. NOTE:Make sure lip of hub removal collet is under fifth/reverse synchronizer hub.

Place Remover Tube T77J-7025-B over countershaft and insert Hub REMOVAL Collet T96P-7025-D as shown.





31. Slide Hub Removal Collet Sleeve T96P-7025-E over collet as shown.





32. Using Forcing Screw T84T-7025-B as shown, remove fifth/reverse synchronizer hub from countershaft cluster gear.






33.NOTE: Identify blocker ring for reassembly.

Remove fifth gear blocker ring from countershaft cluster gear.





34. Remove fifth gear from countershaft cluster gear.





35. Place transmission on bench. Remove Bench Mounted Holding Fixture T57L-500-B adapter from front of transmission mount on rear of transmission as shown. Place transmission and adapter back on holding fixture, rotate to position flywheel housing upright.





36. Remove twelve bolts retaining flywheel housing to case.





37.CAUTION: Pry only in areas shown to prevent damage to case.

Using a suitable pry bar, carefully pry the flywheel housing assembly from case as shown and remove flywheel housing.





38. Remove input shaft (7017) and front bearing from output shaft.





39. Using a Torx 40 bit, remove shift interlock pin from top of case.





40. Remove fifth/reverse near shift rail from case.





41. Using needle nose pliers, remove fifth/reverse shift lever retaining clip.





42. WARNING: REVERSE SHIFT LEVER ANCHOR BOLT WAS INSTALLED USING THREADLOCKER. SIGNIFICANT BREAK-AWAY TORQUE MAY BE REQUIRED, USE CAUTION.

Using Torx 50 bit, remove fifth/reverse shift lever anchor bolt.





43. Remove fifth/reverse shift lever from case.





44. CAUTION: To prevent component damage, do not raise mainshaft assembly by lifting up on third/fourth synchronizer. Push upward on mainshaft assembly approximately 25 mm (one inch) to provide clearance.

Remove countershaft cluster gear.





45. CAUTION: To prevent damage, do not lift output shaft subassembly by third/fourth synchronizer.

Using two hands, carefully lift mainshaft subassembly upward. Remove from case.





46. NOTE: Identify synchronizer assembly for reassembly.

Remove fourth gear blocker ring assembly.