Disassembly
Precaution1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
Clean out all holes and passages with a compressed air, and check that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
Housing Components
NOTE: Do not remove the front and rear oil seals if not necessary.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Extension housing
Turn the extension housing to remove it.
Transmission case
Remove the transmission case from the intermediate housing and gear assembly with the SST.
On-vehicle replacement
Oil seal (rear)
CAUTION: Do not damage the mainshaft splines.
1. Raise the vehicle and support it with safety stands.
2. Drain the transmission oil into a suitable container.
3. Remove the exhaust pipe.
4. Remove the propeller shaft.
5. Remove the oil seal from the extension housing.
6. Apply transmission oil to outer periphery.
7. Install a new oil seal with the SST.
8. Install the propeller shaft.
9. Install the exhaust pipe.
10. Add the specified oil from check plug (A) port until the level reaches the bottom of the check plug hole.
Shift Fork and Shift Rod Parts
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Clip
CAUTION: Hold the spacer and spring to prevent it from jumping out.
Remove the clip, spacer, and spring from the 5th/Reverse shift rod.
Mainshaft and Countershaft Parts
1. Snap ring
2. Washer
3. Retaining ring
4. C-washer
5. Mainshaft rear bearing
6. Retaining ring
7. C-washer
8. Thrust lock washer
9. Steel ball
10. Locknut (Countershaft)
11. Countershaft rear bearing
12. Counter 5th gear
13. Spacer
14. 5th gear
15. Synchronizer ring (5th)
16. Locknut (Mainshaft)
17. Clutch hub assembly (5th/Reverse)
18. Synchronizer ring (Reverse)
19. Reverse gear
20. Needle bearing
21. Inner race
22. Washer
23. Counter reverse gear
24. Main drive gear bearing
25. Snap ring
26. Countershaft front bearing
27. Bearing housing assembly
28. Mainshaft gear assembly
29. Main drive gear
30. Synchronizer ring (4th)
31. Needle bearing
32. Washer
33. Countershaft
34. Synchronizer key spring
35. Clutch hub sleeve
36. Synchronizer key
37. Clutch hub
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Mainshaft rear bearing
Remove the mainshaft rear bearing with the SST.
Locknut (Countershaft)
1. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in the double-engaged condition.
CAUTION:
- Do not reuse the locknut.
- Do not damage the countershaft.
2. Use a suitable tool to uncrimp the tabs of the locknut.
NOTE: Use pads in the vise to prevent damaging the SST.
3. Connect the SST to the mainshaft and tighten it securely in a vise.
4. Remove the locknut.
Countershaft rear bearing
Remove the countershaft rear bearing with the SST.
Locknut (Mainshaft)
1. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in the double-engaged condition.
CAUTION:
- Do not reuse the locknut.
- Do not damage the mainshaft and clutch hub assembly.
2. Use a suitable tool to uncrimp the tabs of the locknut.
NOTE: Use pads in the vise to prevent damaging the bearing housing.
3. Secure the bearing housing in a vise.
4. Remove the locknut with the SST.
Main drive gear bearing
Remove the main drive gear bearing with a suitable pipe
Countershaft front bearing
Remove the countershaft front bearing with the SST.
Bearing housing assembly
Remove the bearing housing by lightly tapping the countershaft with a copper hammer.
Mainshaft Parts
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Clutch hub assembly (3rd/4th)
1. Position the SST between 2nd and 3rd gears.
CAUTION: Hold the mainshaft with one hand so that it does not fall.
2. Press the mainshaft out of the clutch hub assembly (3rd/4th) and 3rd gear.
Clutch hub assembly (1st/2nd)
CAUTION: Hold the mainshaft with one hand so that it does not fall.
Press the mainshaft out of the clutch hub assembly (1st/2nd) and 2nd gear.
Bearing Housing Parts
Disassemble in the order shown in the image referring to Disassembly Note.
Disassembly note
Reverse idler gear shaft
CAUTION: Support the reverse idler gear shaft with one hand so that it does not fall.
Press the reverse idler gear shaft out of the bearing housing.
Mainshaft front bearing
CAUTION: Support the mainshaft front bearing with one hand so that it does not fall.
Remove the mainshaft front bearing with a suitable pipe.
Countershaft center bearing
CAUTION: Support the countershaft center bearing with one hand so that it does not fall.
NOTE: If countershaft center bearing is replaced, replace the spacer also.
Remove the countershaft center bearing with a suitable pipe.
Extension Housing Parts
Disassemble in the order shown in the image.