2. Internal Components Disassemble

^ Tools Required
- J 2619-01 Slide Hammer
- J 8059 Snap Ring Pliers
- J 8092 Driver Handle
- J 29169 Bearing Remover/installer
- J 29369-01 Output Shaft Bearing Remover
- J 33832 Bearing Remover/installer





1. Split the tone wheel with a chisel to remove.
2. Remove the tone wheel snap ring from the mainshaft.
3. Use J 8059 snap ring pliers in order to remove the rear output bearing snap ring from the mainshaft.
4. Remove the case screws from the case halves. These are self-tapping screws. Aluminum shavings are common upon removal.
5. Pry between the two pry bosses in order to separate the two case halves.
6. Remove the rear case half from the front case half.





7. Disconnect the clutch coil wire connector from the clutch coil wire.
8. Remove the three clutch coil nuts from the clutch coil assembly.
9. Remove the clutch coil from the rear case half.
10. Remove the O-ring from the clutch coil.
11. Remove the shift rail spring from the shift rail.





12. Use snap ring pliers in order to remove the clutch coil housing snap ring and the clutch coil housing from the mainshaft.
13. Remove the synchronizer shift collar hub from the synchronizer assembly.





14. Remove the synchronizer assembly from the mainshaft drive gear.
15. Remove the mode shift fork from the shift rail.





16. Remove the one piece sprocket and the shaft from the front output shaft.





17. Remove the drive gear, the driven gear front sprocket, and the drive chain as an assembly from the front output shaft bearing. Note the orientation of the master link.





18. Remove the oil pump assembly and the mainshaft from the input carrier and the front case half.





19. Remove the following components from the input carrier assembly:
^ The shift rail
^ The range fork
^ The shift hub





20. Remove the annulus gear snap ring from the front case.





21. Remove the annulus gear from the front case.
22. Remove the input shaft oil seal from the front case.





23. Remove the carrier assembly snap ring from the carrier assembly input shaft.





24. Remove the input carrier assembly and the power take off drive gear from the front case:





25. Remove the retaining clip from the selector shaft.
26. Remove the selector shaft from the front case.
27. Remove the following components from the front case:
^ The selector
^ The detent spring
^ The detent roller





28. Remove the front input bearing snap ring from the front case.





29. Use the J 8092 and the J 29169 in order to remove the front input bearing from the front case.
30. Use the J 8092 and the J 33832 in order to remove the rear output bearing from the rear case half.





31. Use the J 2619-01 and the J 29369-01 in order to remove the front output shaft rear bearing from the rear case.
32. Remove the front output shaft seal from the front case.





33. Remove the front output bearing snap ring from the front case.





34. Use the J 8092 and the J 33832 in order to remove the front output bearing from the front case.
35. Remove the rear output shaft seal from the rear bearing retainer.
36. Remove the synchronizer hub snap ring from the synchronizer hub assembly.
37. Remove the lockup hub and compression spring from the lockup collar.





38. Remove the mainshaft from the oil pump assembly.
39. Remove the oil pump cover screws and the oil pump cover from the oil pump body.
40. Remove the oil pump drive gear from the oil pump body.
41. Remove the oil pump driven gear from the oil pump body.
42. Remove the retainer from the pick up tube.
43. Remove the pick up tube and the oil pump pickup from the oil pump body.
44. Remove the oil pump pickup from the pickup tube.
45. Remove the retainer ring.
46. Remove the needle bearings from the mainshaft.