Disassembly

DISASSEMBLY




1. Remove drain plug (1) and allow transmission oil to drain.




2. Remove backup lamp switch (1).




3. Remove the bolts (2) holding the shift cable bracket (1) to the transmission case.
4. Remove the bracket from the transmission (1).




5. Remove the nut (4) holding the crossover rod (2) to the shift lever. Be sure to use a wrench (1) to hold the ball stud to prevent it from rotating in the shift lever.




6. Remove bolts (1) holding crossover bellcrank (2) to the transmission case.
7. Remove the crossover bellcrank from the transmission.




8. Be sure to locate the bell crank bushing on the bell crank or the shift lever and set aside for installation.




9. Remove the bolts (1) at the shift lever bracket (2).
10. Remove the shift lever bracket (2).




11. Loosen and remove shift lock ball for the shift detent (5).
12. Loosen and remove shift lock ball for the select detent (3).
13. Loosen and remove shift guide pin (2).




14. Remove the bolts holding the shift lever assembly to the transmission.




15. Remove the shift lever assembly from the transmission case.




16. Remove the bolts (1) holding the transmission case to the clutch housing from inside the clutch housing.




17. Remove the bolts (1) holding the transmission case (2) to the clutch housing (3) from the transmission case side.





18. Insert a flat-blade pry tool (2) at outer edge of axle shaft seals (1).
19. Tap on the pry tool (2) with a small hammer and remove both (case and bell housing sides) axle shaft seals (1).




20. Remove anti-rotation bolt (2) and discard old washer a new washer will be used during assembly.




21. Install a 27 mm (1 1/16 in.) hex adapter (1) into the shaft plug (2) at the rear of the transmission case (3).
22. Loosen and remove the shaft plug (2) in the rear of the transmission case.




23. Using suitable snap-ring pliers (3), release the transmission shaft bearing snap-rings (1, 2) at the rear of the transmission case.




24. Remove the transmission case half (1) from the clutch housing (2).




25. Remove fifth and sixth gear shift rail detent plug (1).




26. Remove fifth and sixth gear shift rail detent spacer (3) and spring (2).




27. Remove fifth and sixth gear shift rail detent ball (2).




28. Remove reverse shift rail detent plug (1).




29. Remove the reverse shift rail detent spacer (3) and spring (2).




30. Remove the reverse shift rail detent ball (2).




31. Remove third and fourth gear shift rail detent plug (1).




32. Remove third and fourth gear shift rail detent spacer (3) and spring (2).
33. Remove third and fourth gear shift rail detent ball.




34. Remove third and fourth gear shift rail detent ball (2).




35. Remove first and second gear shift rail detent plug (1).
36. Remove first and second gear shift rail detent spacer and spring.




37. Remove first and second gear shift rail detent ball (3).




38. Remove the bolt (1) holding the reverse shift fork (5) to the reverse shift rail (6).




39. Remove the reverse shift rail from case and shift fork.




40. Remove the bolt (2) holding the fifth and sixth gear shift fork (3) to the fifth and sixth gear shift rail (1).




41. Remove the fifth and sixth gear shift rail (1) from case and shift fork (2).




42. Remove the reverse gear shift fork (1).




43. Remove the fifth and sixth gear shift fork (2).




44. Remove the bolt (2) holding the first and second gear shift fork (3) to the rail.




45. Using a hammer and a punch (3) remove the roll pin at the third and fourth gear shift fork to rail (1).




46. Remove the first and second gear shift rail (1).




47. Using a hammer and a punch (3) remove the roll pin at the third and fourth gear shift rail.




48. Remove the third and fourth gear shift rail (1) from case and shift fork (4).




49. Remove the third and fourth gear shift bracket (1).




50. Remove the E-clip and shift rail bracket pivot pin (1).




51. Remove the pivot shaft (1) from case.




52. Remove the shift rail pivot bracket (1) from the stand (2).




53. Remove the third and fourth gear shift fork (1) from synchronizer.




54. Remove the first and second gear shift fork (1) from synchronizer (2).




55. Remove the reverse idler gear (1) hold down bolt (2).




56. Remove the bolts (2) at the oil slinger (1) and remove the oil slinger.




57. Remove the output shaft #2 (1) from case.




58. Remove the reverse idler gear (1), shaft, bearing and thrust washer from the case.




59. Remove the output shaft (2) hold down bolt (4) from the case.




60. Remove the output (1) and input (2) from case together.




61. Remove the differential (1) from the case (5).




62. Remove the magnet (1) from the case.




63. Remove the oil feed trough (1) from the case.




64. Remove the bolts (1) holding the oil baffle.
65. Remove the oil baffle (2).