Warner T5 (77mm) 5-Speed

Fig. 1 (1 of 2):

Fig. 1 (2 of 2):

Fig. 2 Removing Offset Lever Pin:

Fig. 3 Removing Detent Ball & Spring:

5th Gear And Reverse Shift Shaft:

1. Remove drain plug, Fig. 1, drain lubricant. Except for fill plug and gear shift lever attaching bolts, all threaded holes and bolts used in the model T5 transmission case have metric threads. When using replacement bolts be sure they are the same size and length as originals.
2. Using pin punch and hammer, Remove offset lever to shift rail attaching roll pin Fig. 2.
3. Remove adapter housing to transmission case bolts, then remove housing and offset lever as an assembly. Do not attempt to remove offset lever while adapter housing is still bolted in place. Lever has a positioning lug engaged in housing detent plate which prevents moving lever far enough forward for removal.
4. Remove detent ball and spring from offset lever and remove roll pin from adapter housing or offset lever Fig. 3, then remove plastic funnel, thrust bearing race and thrust bearing from rear of countershaft. (Countershaft rear thrust bearing, washer and plastic funnel may be found either on the end of countershaft or inside adapter housing.)
5. Remove transmission cover and shift fork assembly attaching bolts, noting location of the two alignment type dowel bolts for assembly reference and remove cover.
6. Using hammer and punch, remove roll pin from 5th gear shift fork, being sure to place wood block under fork during removal of roll pin to prevent damage to 5th gear/reverse shift rail.
7. Remove 5th gear synchronizer snap ring, shift fork, 5th gear synchronizer sleeve, blocking ring and 5th speed drive gear from rear of countershaft.
8. Remove 5th gear insert retainer synchronizer springs and inserts from sleeve and hub, marking position of sleeve and hub for assembly reference.
9. Using snap ring pliers tool No. J-25215 or equivalent, remove snap ring and 5th speed driven gear from rear of output shaft.
10. Mark position of front bearing cap on front of transmission case for assembly reference.
11. Remove front bearing cap bolts and front bearing cap, then remove front race and endplay shim(s) from cap and remove oil seal from cap using screwdriver.
12. Turn clutch shaft so that flat surface on main drive gear faces countershaft and remove clutch shaft from transmission case, then remove 15 clutch shaft needle bearings, thrust bearing and race.
13. Remove output shaft rear bearing race, then tilt output shaft assembly upward and remove assembly from transmission case.
14. Unhook over center link spring from rear of transmission case.
15. Remove C-clip attaching reverse lever and fork assembly-to-reverse lever pivot pin.
16. Turn 5th gear/reverse shift rail clockwise (sa viewed from top of transmission) to disengage rail from reverse lever assembly, then remove rail from rear of case.
17. Remove fork assembly and reverse lever pivot pin and detach reverse lever from reverse idler gear, then remove reverse lever and fork assembly from case.
18. Remove rear countershaft snap ring and spacer, then insert brass drift through clutch shaft opening in front of transmission case and using arbor press, press countershaft assembly rearward to remove rear countershaft bearing. When properly installed, bearing identification numbers face outward.
19. Move countershaft assembly rearward inside case, then tilt upward and remove from case. Remove front countershaft thrust washer from case, noting washer position for assembly reference.
20. Remove countershaft rear bearing spacer, then remove roll pin from forward end of reverse idler shaft using hammer and punch.
21. Remove reverse idler shaft and gear from transmission case, noting gear position for assembly reference.
22. Using arbor press, remove countershaft front bearing from case.
23. Using bearing remover tool No. J-29721 and No. J-22912-01 or equivalent, remove clutch shaft front bearing.
24. Using screwdriver, remove rear adapter housing seal.