Disassembly

1. Install suitable bolts and washers in intermediate plate. Then clamp plate and gear assembly in vise. Use enough washers to prevent bolts from touching. Also be sure vise jaws are clamped on bolt heads.
2. Measure thrust clearance between countershaft fifth gear and thrust ring with feeler gauge. Clearance should be 0.10 to 0.40 mm (0.003 to 0.019 inch). If clearance exceeds limits, gear and/or ring will have to be replaced.





3. Remove countershaft fifth gear retaining snap-ring.





4. Remove bolt holding fifth gear shift fork to shift rail.
5. Move fifth gear shift rail forward until the rail is clear of the shift fork.





6. Remove the fifth gear shift fork from the synchronizer sleeve.





7. Remove the reverse shift head and rail assembly from the intermediate plate.





8. Remove fifth gear blocker ring from countershaft assembly with Puller L-4407, or equivalent.





9. Remove fifth gear synchro ring.





10. Remove the countershaft fifth gear assembly from countershaft.





11. Remove fifth gear thrust ring from countershaft.





12. Remove fifth gear thrust ring lock ball from countershaft.

NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission. Whenever a pin or ball is removed, it should be identified in such a way that it can be reinstalled in the same location from which it was removed.





13. Remove bolts holding output shaft rear bearing retainer to intermediate plate.





14. Remove rear bearing retainer.





15. Remove reverse idler gear shaft and gear.





16. Remove bolts holding reverse shift arm bracket to intermediate plate.





17. Remove threaded lock ball plugs from intermediate plate.





18. Then remove lock ball and spring from plug holes with pencil magnet.





19. Remove the fifth gear shift rail.





20. Retrieve the fifth gear shift rail lock ball from the intermediate plate using a magnet.





21. Remove the 1-2 and 3-4 shift rail c-rings using two equally sized screwdrivers.





22. Remove bolts holding 1-2 and 3-4 shift forks to the shift rails and discard bolts.





23. Remove the 3-4 shift rail from the 1-2 and 3-4 shift forks and the intermediate plate.





24. Remove the 3-4 shift rail interlock plug from the intermediate plate with a small magnet.





25. Remove the 3-4 shift fork.





26. Remove the 1-2 shift rail from the 1-2 shift fork and the intermediate plate.





27. Remove the 1-2 shift rail interlock pin from the 1-2 shift rail.





28. Remove the 1-2 shift rail interlock plug from the intermediate plate.
29. Remove the 1-2 shift fork.





30. Remove the c-ring holding the reverse shift rail into the intermediate plate using two equally sized screwdrivers.





31. Remove the reverse shift rail and fork from the intermediate plate.





32. Remove the interlock pin from the reverse shift rail.





33. Remove snap-ring holding output shaft rear bearing into the intermediate plate.
34. Remove countershaft rear bearing snap-ring.





35. With aid of an assistant, support the mainshaft and countershaft. Tap on the rear of the mainshaft and countershaft with a suitable rubber mallet. This will release the countershaft from the countershaft rear bearing and the mainshaft rear bearing from the intermediate plate. The mainshaft will release from the intermediate plate first and can be removed by moving the mainshaft rearward and upward.
36. Remove the countershaft by moving the countershaft rearward until the countershaft is clear of the intermediate plate.
37. Remove the countershaft rear bearing from the intermediate plate.