Transmission Disassembly (Rear Wheel Drive)

TRANSMISSION DISASSEMBLY (REAR WHEEL DRIVE)

- Tools Required
- J21427-01 Speedometer Gear Puller Adapter
- J23907 Slide Hammer
- J24420-B Gear Puller
- J26941 Output Shaft Oil Seal Remover
- J3289-20 Base Holding Fixture
- J36509 Detent Sprint Plug Remover
- J36515 Assembly Pallet
- J36515-15 Mainshaft Adapter
- J36515-16 Countershaft Adapter
- J36824 Transmission Adapters
- J8763-02 Holding Figure C-Clamp
- J8763-21 Balance Bracket for C-Clamp





1. Remove 2 reverse idler shaft support bolts.





2. Remove 2 lower-housing bolts. Tool J3289-20 must be mounted securely on a sturdy workbench.





3. Assemble the transmission holding fixture:
3.1. The J8763-21 onto the J8763-02
3.2. The J36824 onto the transmission housing
3.3. The J8763-02 onto the J36824
3.4. The J8763-02 onto the J3289-20





4. Remove the backup lamp switch assembly.





5. Remove the shift shaft block-out bushing pin.





6. Remove the following components:
6.1. The bolt
6.2. The vehicle speed sensor





7. Complete the following tasks:
7.1. Remove the detent plug. Use the J36509 and the J23907.
7.2. Remove the detent spring and the detent plunger.





8. Position the transmission vertically. Remove the following components:
8.1. The 6 bolts
8.2. The input shaft bearing retainer
9. Tap the clutch release bearing pilot with a rubber mallet.





10. Remove the input shaft snap ring.





11. Position the transmission horizontally.
Remove the front housing to the rear housing bolts.





12. Drive the 2 dowel pins into the front housing.





13. Remove the front housing.





14. Remove the countershaft bearing.





15. Remove the reverse idler shaft support. The idler shaft support will snap out.





16. Move all of the shift forks forward. Engage the 4th gear, the 2nd gear, and Reverse gear.
Retain the shift lever detent plunger and spring.





17. Remove the shift shaft lever roll pin.
17.1. Rotate the shift shaft lever finger down.
17.2. Support the shift shaft end.
17.3. Drive out the roll pin.
17.4. Ensure that the roll pin clears the 2nd speed gear.





18. Shift all of the gears into neutral.





19. Engage the 5th speed gear.





20. Push the shift shaft into the housing.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.





21. Remove the shift shaft socket roll pin.
21.1. Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.
21.2. Support the shift shaft end.
21.3. Drive out the roll pin. Use a 5 mm (3/16 inch) punch. The roll pin will fall into the transmission housing.





22. Remove the following components:
22.1. The shift shaft
22.2. The shift shaft socket
22.3. The shift shaft lever
22.4. The shift shaft block-out bushing





23. Remove the 3rd/4th speed gear shift fork.
Rotate counterclockwise.





24. Loosen 3 bolts on the rear of the housing. Do not remove the bolts.





25. Install the tool J36515-15 on the input shaft.
26. Install the tool J36515-16 on the countershaft.
27. Install the tool J36515 to the transmission assembly.





28. Remove tools J8763-02 and J36824 from the transmission housing.





29. Remove the 3 bolts from the rear housing.





30. Remove the rear housing. Tap the rear housing with a rubber mallet.





31. Remove the mainshaft bearing retainer.





32. Remove the following components:
32.1. 2 shift forks (1)
32.2. The reverse idler gear (2)
32.3. The countershaft (3)
32.4. The countershaft bearing (4)





33. Remove the vehicle speed sensor reflector wheel. Use the J21427-01 and the J24420-B
Discard the reflector wheel.





34. Remove the following components:
- The rear mainshaft bearing snap ring (1)
- The rear mainshaft bearing (2)





35. Remove the mainshaft assembly from the assembly pallet J36515. Remove the following parts:
- The input shaft
- The mainshaft pilot bearing from the input shaft