Disassembly

DISASSEMBLY




MAJOR COMPONENTS

Important Operations




2. Transfer Flange
Use the transfer flange holder to remove the transfer flange.

Transfer Flange Holder : J-37221




3. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission case.

4. Counter Gear Snap Ring




5. Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring. Snap Ring Pliers

Transfer Case Assembly And Mainshaft Gear:

MINOR COMPONENTS

Important Operations




7. 2-4 Shift Rod
1. Engage the 2nd-4th sleeve with the front output gear.
2. Remove the spring pin from the block.
3. Remove the shift rod.




12. Interlock Pin
Use a magnetic hand to remove the interlock pin from the transfer case.




13. High-Low Shift Rod
Use a spring pin remover to remove the shift arm spring from the shift arm and the shift rod.
Spring Pin Remover
Discard the used spring pin.

16. Bearing Snap Ring




17. Mainshaft End Ball Bearing
1. Use a pair of snap ring pliers to remove the snap ring.
Snap Ring Pliers
2. Use a bearing remover to remove the ball bearing.

Remover : J-37217
: J-8433




18. Mainshaft End Lock Nut and Washer
1. Engage the 3rd-top synchronizer with the 3rd gear.
2. Engage the low-2nd synchronizer with the low gear.
3. Use the lock nut wrench to remove the lock nut.

Lock Nut Wrench : J-37219

19. High-Low Synchronizer Assembly

20. High-Low Block Ring




21. Transfer Input Gear
Use the universal puller to remove the high-low synchronizer assembly, the high-low block ring, and the transfer input gear.
Universal Puller:




24. Bearing Snap Ring
Use a pair of snap ring pliers to expand the bearing snap ring.
Snap Ring Pliers
Use a plastic hammer to tap the front output gear assembly free.




35. Ball Bearing
Use a bench press and the bearing remover to remove the ball bearing.

Bearing Remover : J-22912-01

38. Bearing Snap Ring

39. Ball Bearing

40. Bearing Inner Snap Ring




41. Ball Bearing
1. Use a pair of snap ring pliers to remove the snap rings.
Snap Ring Pliers
2. Use a bench press and the bearing remover to remove the ball bearings.

Bearing Remover : J-22912-01




TRANSFER REAR CASE ASSEMBLY

Important Operations

2. Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
Snap Ring Pliers

4. Bearing Snap Ring

5. Ball Bearing




6. Bearing Snap Ring
1. Use a pair of snap ring pliers to remove the snap rings.
Snap Ring Pliers
2. Use a bench press and the bearing remover to remove the ball bearing.

Bearing Remover : J-22912-01

9. Bearing Snap Ring




10. Ball Bearing
1. Use a pair of snap ring pliers to remove the snap ring.
Snap Ring Pliers
2. Use a bench press and the bearing remover to remove the ball bearing.

Bearing Remover : J-22912-01




INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT FORK ASSEMBLY, AND INTERLOCK PIN

Important Operations




3. Detent Ball
Use a magnetic hand to remove the detent balls from the intermediate plate.
Take care not to lose the detent balls.

8. 3rd-4th Shift Rod

9. 3rd-4th Shift Arm

10. 1st-2nd Shift Arm




1. Hold a round bar against the shift arm end.
This will prevent damage to other components.




2. Use a spring pin remover to remove the shift arm spring pin from the shift arm and the shift rod.
Spring Pin Remover
Discard the used spring pin.
3. Move the 3rd-4th shift rod forward.
Take care not to lose the interlock pins.




REVERSE GEAR AND 5TH GEAR

Important Operations

1. Oil Seal Collar

2. Roller Bearing




3. Retainer
1. Set the retaining ring remover (1) to the retainer (2) and the mainshaft end (3).
2. Remove the retainer together with the ball bearing (4) and the oil seal collar (5).

Retainer Remover : J-8433

The universal puller may be used in place of the retaining ring remover.

Universal Puller : J-8433




6. Reverse Gear Snap Ring
Use a pair of snap ring pliers to remove the snap ring. Snap Ring Pliers

8. Ball Bearing




9. Counter 5th Gear
1. Use a pair of snap ring pliers to remove the snap rings.
Snap Ring Pliers
2. Attach the bearing remover to the counter 5th gear
Use the bearing remover to remove the ball bearing and the counter 5th gear and together with reverse idler gear assembly.

Bearing Remover:

18. Clutch Hub Nut




1. Engage the 3rd-top synchronizer with the 3rd gear.
2. Engage the 1st-2nd synchronizer with the 1st gear.
3. Attach the holding fixture together with the holding base to the mainshaft front bearing and the counter gear front bearing.

Holding Fixture : J-37224
Holding Base : J-3289-20




4. Use the hub nut wrench to remove the hub nut.

Hub Nut Wrench : J-37219




23. Bearing Plate and Screw
Use the torx bit to remove the bearing plate screw from the intermediate plate.

Torx Bit Wrench : J-37225 (T45)

24. Bearing Snap Ring




25. Intermediate Plate
1. Insert the snap ring pliers into the mainshaft bearing snap ring hole.
2. Use the snap ring pliers (1) to force open the mainshaft bearing snap ring (2).
Hold the snap ring open with the pliers.
3. Push the intermediate plate toward the rear of the transmission to remove it.
The ball bearing snap ring will come free.




TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR

Important Operations

1. Top Gear Shaft Snap Ring

2. Top Gear Shaft




3. Ball Bearing
1. Use a pair of snap ring pliers to remove the snap ring. Snap Ring Pliers
2. Use a bench press and the bearing remover to remove the ball bearing.

Bearing Remover : J-22912-01




6. Mainshaft Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
Snap Ring Pliers




7. 3rd-4th Synchronizer Assembly
1. Use a bench press and the bearing replacer to remove the synchronizer assembly as a set.
2. Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

11. Needle Bearing Collar

12. Mainshaft Ball Bearing

13. 1st Gear Thrust Bearing




14. 1st Gear
Use a bench press and the bearing remover to remove the ball bearing.

Bearing Remover:




17. Clutch Hub Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
Snap Ring Pliers

18. 1st-2nd Synchronizer Assembly

19. 2nd Block Ring




20. 2nd Gear
1. Use a bench press and the bearing remover to remove the ball bearing 2nd gear together with synchronizer assembly.

Remover : J-22912-01

2. Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts




24. Front Ball Bearing
Use a bench press and the bearing remover to remove the ball bearings.

Bearing Remover : J-22912-01