Disassembly
DISASSEMBLYADAPTER/EXTENSION HOUSING
1. Drain transmission lubricant, if necessary.
2. Remove release bearing and lever.
3. Remove clutch housing bolts and remove housing (Fig. 8).
4. Remove vehicle speed sensor and speedometer adapter, if necessary.
5. Remove shift tower bolts and remove tower from transmission (Fig. 9).
6. Remove shift tower gasket from shift tower or transmission (Fig. 10).
7. Remove detent ball plug (Fig. 11).
8. Remove detent spring (Fig. 12) and ball (Fig. 13) with pencil magnet.
9. Remove shift arm retainer bolt (Fig. 14).
10. Remove shift arm restrictor pins (Fig. 15).
NOTE: Restrictor pins are not interchangeable, they are color coded. Note color and location of restrictor pins for installation reference.
11. Remove shift lever shaft plug (Fig. 16).
12. Remove shifter shaft with large magnet (Fig. 17).
13. Remove shift arm from the adapter housing.
14. Remove adaptertension housing bolts.
15. Loosen adaptertension housing by tapping it loose with rawhide/rubber hammer (Fig. 18).
16. Remove adaptertension housing (Fig. 19).
17. On 4x2 transmissions, remove speedometer gear retaining snap-ring from output shaft. Remove speedometer gear from output shaft and remove speedometer gear lock ball from output shaft. Remove speedometer drive gear locating snap-ring (Fig. 20).
18. Remove bolts holding front bearing retainer to the transmission case.
19. Remove bearing retainer from transmission case (Fig. 21).
20. Remove input shaft bearing snap-ring (Fig. 22).
21. Remove countershaft front bearing snap-ring.
22. Separate intermediate plate and transmission case by tapping them loose with rawhide/rubber hammer (Fig. 23).
23. Separate intermediate plate from the transmission case (Fig. 24).
GEARTRAIN AND SHIFT MECHANISM
1. Install suitable bolts and washers in intermediate plate (Fig. 25). Then clamp plate and gear assembly in vise on bolt heads. Use enough washers to prevent bolts from touching.
2. Remove countershaft fifth gear retaining snap-ring (Fig. 26).
3. Remove bolt holding fifth gear shift fork to shift rail (Fig. 27).
4. Remove fifth gear blocker ring from countershaft assembly with Puller L-4407 (Fig. 28).
5. Remove fifth gear synchro ring (Fig. 29).
6. Remove countershaft fifth gear assembly from countershaft (Fig. 30).
7. Remove fifth gear thrust ring from countershaft (Fig. 31).
8. Remove fifth gear thrust ring lock ball from countershaft (Fig. 32).
CAUTION: Lock balls, check balls, interlock balls, and interlock pins are used in various places in the transmission. Pins or balls must be identified and marked for installation reference.
9. Remove bolt holding reverse idler gear shaft lock plate to the intermediate plate.
10. Remove reverse idler gear shaft and reverse idler gear assembly (Fig. 33).
NOTE: Retrieve pin and compression spring from the reverse idler shaft.
11. Remove output shaft rear bearing retainer bolts and remove retainer (Fig. 34).
12. Remove bolts holding 1-2 and 3-4 shift forks to the shift rails (Fig. 35) and discard bolts.
13. Remove bolts holding reverse shift arm bracket to intermediate plate (Fig. 36).
14. Remove snap-ring holding output shaft rear bearing into the intermediate plate (Fig. 37).
15. Remove countershaft rear bearing snap-ring.
16. With an assistant, support the mainshaft and countershaft. Tap on the rear of the mainshaft and countershaft with a plastic mallet. This will release the countershaft from the countershaft rear bearing and mainshaft rear bearing from the intermediate plate. The countershaft will release from the countershaft bearing first and can be removed by moving the countershaft rearward and downward (Fig. 38).
17. Remove the mainshaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks (Fig. 39).
18. Remove 3-4 shift fork from the 3-4 shift rail (Fig. 40).
19. Remove snap-ring from 1-2 shift rail to allow the removal of the 1-2 shift fork.
20. Remove 1-2 shift fork from the 1-2 and the 3-4 shift rails (Fig. 41).
21. Remove threaded plugs from intermediate plate. Then remove lock ball and spring from with pencil magnet (Fig. 42).
NOTE: The bottom spring is shorter in length than the other two springs.
22. Remove intermediate plate from the vise, rotate the plate 180°, and reinstall plate in the vise using the same bolt and washer mounting set-up.
CAUTION: Interlock balls and pins are different sizes and shapes. Pins and balls must be identified and marked for installation reference.
23. Remove fifth gear shift rail (Fig. 43).
24. Remove fifth gear check ball (Fig. 44) and interlock pin.
25. Remove reverse shift head and rail assembly (Fig. 45).
26. Remove snap-ring holding reverse shift rail into intermediate plate.
27. Remove reverse shift rail and reverse shift fork and arm assembly from intermediate plate (Fig. 46).
28. Remove interlock pin from reverse shift rail (Fig. 47).
29. Remove reverse elongated check ball (Fig. 48).
30. Remove snap-ring on 3-4 shift rail.
31. Remove 1-2 shift rail from intermediate plate.
32. Remove interlock pin from 1-2 shift rail (Fig. 49).
33. Remove 1-2 shift rail elongated check ball from intermediate plate (Fig. 50).
34. Remove 3-4 shift rail from intermediate plate.