Disassembly
DISASSEMBLYTransmission
Special Tool(s)
1. WARNING: Wear protective eyewear whenever using compressed air.
Clean the transmission exterior with solvent, and dry with compressed air.
2. WARNING: Wear protective eyewear whenever using compressed air.
Clean all parts removed with solvent, and dry with compressed air.
3. Remove the clutch release hub and bearing.
4. Using the special tool, secure the transmission to a suitable workbench.
5. If not previously done, drain the transmission fluid.
6. Remove the bolts and the lower shift lever retainer.
7. NOTE: It is not necessary to remove the shift housing. The extension housing can be removed with the shift housing attached.
Remove the bolts and the shift housing assembly.
Carefully pry the shift housing to break the gasket seal.
8. Remove the 10 bolts and the extension housing.
Carefully pry the extension housing to break the gasket seal.
9. NOTE: Inspect the bearings for wear or damage before removing.
Disassemble the extension housing.
1 Remove the snap rings.
2 Remove the extension housing bearings.
^ If the output bearing cannot be removed by hand, use a slide hammer and an internal puller.
3 Remove and discard the output seal.
10. Install the special tool on the input shaft and to the clutch housing.
11. Unstake and remove the output shaft locknut.
Push forward on the center rail to lock the transmission in gear.
12. Unstake and remove the countershaft rear locknut.
Position the transmission with the output shaft facing upward.
13. Remove the output shaft bearing and the countershaft rear bearing. Use the special tools to remove both rear bearings.
14. Remove the output shaft gear, the fluid slinger ring and the mainshaft fifth gear.
15. Remove the shift rail friction plugs, the friction springs and the friction spring seats.
16. Using a hammer and 5 mm or 3/16 inch punch, tap the roll pins out, then remove the shift rail ends.
17. Remove the reverse lamp switch and the reverse lamp switch pin.
18. Remove the five bolts and the shift fork lock plates. Discard the O-rings.
Rotate the shift fork lock plates 90 degrees to remove.
19. Remove the reverse idler gear bolt.
20. Remove the 10 bolts, then carefully lift the main case off the clutch housing.
Carefully pry the main case to break the gasket seal.
21. Remove the Output Shaft Speed (OSS) sensor.
22. Remove the output shaft.
23. Remove the shim.
24. Remove the spacer and the bearing cup.
^ Inspect the bearing cup and bearing for wear or damage. Install a new bearing and bearing cup as necessary.
^ Install a new bearing and cup in a set only. Do not install one without the other.
25. Using the special tool, remove and discard the output shaft bearing.
^ Install a new bearing and cup in a set only.
26. NOTE: Remove the shift rail detent plugs, detent springs and the check balls one shift rail at a time.
Remove the third and fourth gear shift rail detent plug, detent spring and the check ball.
Use a magnet to remove the dent springs and check balls.
27. Remove the shift forks and shift rails.
1 Remove the third and fourth shift fork and the shift rail.
2 Remove the shift rail detent plug, detent spring and the check ball, then remove first and second gear shift fork and shift rail.
3 Remove the shift rail detent plug, detent spring and the check ball, then the fifth and reverse shift rail.
^ Inspect the shift rails and shift rail stops for wear or damage. Disassemble and install new components as necessary.
28. Remove the reverse idler gear assembly.
1 Remove the snap ring.
2 Using a punch, tap the pin out.
3 Remove the reverse idler gear.
^ Inspect the idler shaft and gear for wear or damage. Install new components, as necessary.
29. Remove the fifth and reverse gear shift fork.
30. Inspect the shift fork pads for wear or damage. Install new pads as necessary.
31. NOTE: Secure the Bearing/Oil Seal Plate in a vise.
Carefully remove the countershaft assembly.
^ Place the countershaft in the Bearing/Oil Seal
^ Plate with the input shaft facing upward.
32. NOTE: Remove the special tool.
Remove the mainshaft and set it aside.