Disassembly

Transmission Disassembly

Tools Required

- J 23907 Slide Hammer with Pilot Bearing Puller
- J 3289-20 Base Holding Fixture
- J 36509 Detent Spring Plug Remover
- J 36515 Assembly Pallet
- J 36515-15 Mainshaft Adapter
- J 36515-16 Countershaft Adapter
- J 36824 Transmission Adapters
- J 36825 4WD Output Shaft Oil Seal Remover
- J 8763-02 Holding Fixture C-Clamp
- J 8763-21 Balance Bracket for C-Clamp




1. Remove the two reverse idler shaft support bolts




2. Remove two housing bolts




3. Assemble the transmission holding fixture:
1. J 8763-21 onto J 8763-02
2. J 36824 onto the transmission housing
3. J 8763-02 onto J 36824
4. J 8763-02 onto J 3289-20
5. Mount tool J 3289-20 securely on a sturdy workbench.




4. Remove the backup lamp switch assembly.




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




6. Remove the following components:
1. The detent plug. Use J 36509 and J 23907.
2. The detent spring
3. The detent plunger




7. Remove the output shaft oil seal. Use J 36825 and J 23907.
Use J 36825 by screwing it into one of the three perforated holes in the seal.




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




9. Remove the input shaft snap ring.




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




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




12. Remove the front housing.




13. Remove the countershaft bearing.




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




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




16. Remove the shift shaft lever roll pin.
1. Rotate the shift shaft lever finger down.
2. Support the shift shaft end.
3. Drive out the roll pin.
4. Ensure the roll pin clears the 2nd speed gear.




17. Shift all the gears into neutral.




18. Engage the 5th speed gear.

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




19. Push the shift shaft into the housing.




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




21. Remove the following components:
1. The shift shaft
2. The shift shaft socket
3. The shift shaft lever
4. The shift shaft block-out bushing




22. Remove the 3rdl4th speed gear shift fork. Rotate counterclockwise




23. Install tool J 36515-15 on the input shaft.
24. Install tool J 36515-16 on the countershaft.
25. Install J 36515 to the transmission assembly with the adapters and transmission assembly upright on the work bench.




26. Remove J 8763-02 and J 36824 from the transmission housing.




27. Remove the mainshaft bearing snap ring.




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




29. Remove the following components:
1. Two shift forks (1)
2. The reverse idler gear (2)
3. The countershaft (3)
4. The countershaft bearing (4)




30. Remove the mainshaft assembly from the assembly pallet J 36515. Remove the following parts:
- The input shaft
- The mainshaft pilot bearing from the input shaft

Rear Housing Disassembly

Tools Required

- Hydraulic Press
- J 23907 Slide Hammer with Pilot Bearing Puller




1. Remove the rear housing shift shaft bearing. Use tool J 23907 with a suitable pilot bearing puller.
- Install the puller legs behind the bearing lip.
- If the bearing lip breaks OFF, install the puller legs behind the inside (outer end) bearing lip.




2. Drive out 2 dowel pins.




3. Remove the following components:
1. 3 bolts
2. The output shaft bearing retainer




4. Remove the output shaft bearing assembly. Use a brass drift.
5. Remove the gasket material from the housing. Use liquid gasket remover.


Front Housing Disassembly

Tools Required

- Hydraulic Press
- J 6125-1B Slide Hammer
- J 23907 Slide Hammer with Pilot Bearing Puller
- J 36183 Input Shaft Press Tube with Cap
- J 36184 Adapter Press Tube
- J 36507 Detent Bushing Remover/Installer
- J 36510 Clutch Fork Pivot Remover/Installer
- J 36511 Oil Fill Plug Hex Bit (17 mm) J 36800 Shift Rail Bushing Remover




1. Use the following tools in order to press out the input shaft bearing:
- A hydraulic press
- J36183
- J36184




2. Remove the shift shaft front housing bushing. Use tool J 36800 and tool J 23907.




3. Remove the clutch fork pivot. Use tool J 36510 and tool J 6125-1B.
1. Put 1 additional nut (3/8-16 thread) on tool J 36510.
2. Install tool J 6125-1B on the nut.
3. Tighten both nuts.




4. Remove two detent lever bushings.
- Use tool J 36507, if necessary
Remove one bushing at a time.




5. Remove the transmission housing vent assembly. Do not remove the metal tube from the housing.




6. Remove the oil fill plug. Use tool J 36511.




7. Remove the oil drain plug. Use tool J 36511.
8. Remove the gasket material from the housing. Use a liquid gasket remover.

Input Shift Bearing Retainer Assembly

Removal Procedure




Remove the seal from the main drive gear bearing retainer. Pry the seal out with a small pry bar or the equivalent.