Extension Housing Disassembly
Extension Housing DisassemblyComponent Identification: Transmission Extension Housing
1. Remove the Clutch Release Bearing
- Pull the bearing straight off until it releases
2. Remove the Clutch Release Fork
- Force the spring apart from behind with your fingers to release the spring
3. Remove the Clutch Fork Dust Cover
Optional Step
4. Remove the Shift Fork Pivot Pin (17mm)
- Only remove the Pivot Pin to replace it if it is worn or damaged
5. Remove the Fill Plug and Gasket (24mm)
6. Remove the Drain Plug and Gasket (24mm)
- Drain all lubricant from the transmission
7. Remove the Speedometer Sensor bolt (10mm)
- Remove the sensor
8. Remove the Neutral Switch (27mm)
9. Remove the Backup Light Switch and Gasket (27mm)
Combine Step 10 and 11
10. Remove the control case housing bolts (four-12mm)
- Remove the Control Case Housing
11. Remove the Control Case Housing Gasket
12. Remove the Control Rod End set-Bolt (12mm)
13. Remove the extension housing bolts (eight-12mm)
- Remove the Extension Housing. You will have to break the sealant loose by using pry-bars on the tabs between the housing halves
- The Control Rod End {part #12} will come out with the Extension Housing
Combine Step 14 thru 17
14. Remove the E-clip from the neutral torsion spring
15. Remove the Neutral Torsion Spring
16. Remove the Control Rod Lever and
17. the Control Rod as an assembly
18. Remove and clean the Oil Pass (10mm bolt)
19. Clean and inspect the Stopper Block (two- 12mm bolts)
- This component limits the travel of the Control Rod assembly {part #16 &17}
20. Clean the Oil Funnel
21. Clean and inspect the Lever Support (12mm)
- Make sure there is a good fit between the Lever Support and the Control Rod {part #16}
- The Lever Support is the front bushing for the Control Rod {part #17}
22. Make sure the Breather is clear
23. Clean the Baffle Plate
- If you must remove it, use long needle nose pliers
Combine Step 24 and 25 to replace the rear Control Rod Bushing
24. Place the extension housing onto rags to protect the housing
- Remove the plug from the rear of the transmission using a suitable drift or punch
- This plug allows access to remove the extension housing bushing {part #25}
This step is for replacement of the rear Control Rod Bushing in the extension housing
25. Place the extension housing onto rags to protect the housing
- Tap out the extension housing bushing using a suitable drift or punch
26. Place the extension housing onto rags to protect the housing
- Use a drift or punch to remove the Oil Seal
27. Remove the outer speedometer drive gear Snap-Ring
(Discard the Snap-Ring. It must be replaced)
28. Remove the speedometer Drive Gear
29. Remove the Steel Speedometer Index Ball{29} and place it in the bag marked Springs and Steel Detent Balls
- Remove the inner speedometer drive gear Snap-Ring{27}
(Discard the Snap-Ring. It must be replaced)
- Write down any parts that need replacement on the Repair Order