A. Transmission Case Disassembly

Clean
- Exterior of the transmission assembly thoroughly with appropriate solvent.
- Remove drain bolt on transmission case and drain lubricant.

^ Tools Required
- J 37359 Countershaft Bearing Remover
- J 22912-01 Bearing and Gear Puller

NOTICE: Removal of offset lever in position other than neutral (centered) may result in driving the roll pin into the detent plate without releasing lever, making further disassembly extremely difficult.
- Position offset lever in neutral gate (centered).





DISASSEMBLE
1. Roll pin attaching offset lever to shift rail.





2. Extension housing-to-transmission case bolts.

NOTICE: Do not attempt to remove the offset lever while the extension housing is still bolted in place. The lever has a positioning lug engaged in the housing detent plate, which prevents moving the lever far enough for removal.

3. Housing and offset lever as an assembly.





4. Detent ball and spring from offset lever.
5. Roll pin from extension housing and offset lever.





6. Oiling funnel from rear of countershaft.
7. Bolts attaching transmission cover and shift fork assembly to case.
- Two of the transmission cover attaching bolts are alignment type dowel bolts. Note the location of these bolts for assembly reference.





8. Cover.





9. Reverse lever spring clip, pivot bolt and shift lever.
10. Backup lamp switch.





11. 5th gear synchronizer snap ring and retainer from rear of countershaft.





12. Unhook 5th/reverse lever return spring from side of transmission case.





13. 5th gear, synchronizer, shift fork, and shift rail as an assembly. If necessary, rotate rail to disengage from reverse lever assembly.
14. Circlip, speedometer reluctor ring and retaining clip.





15. Snap ring from 5th speed driven gear.





16. Front bearing retainer bolts.
17. Front bearing retainer.
18. Front bearing race and end play shims from front bearing retainer.





19. Rotate drive gear until flat surface faces countershaft and remove drive gear from the transmission case.
- Be careful not to drop the IS roller bearings, thrust bearing, or race from the rear of drive gear.
20. 4th gear blocker ring from 3rd/4th synchronizer.





21. Mainshaft rear bearing race.
A. If the race sticks, it is probably misaligned in the case bore. To free the race, work the shaft back and forth in the case.
B. Tilt mainshaft upward and remove assembly from transmission case.
22. Reverse fork assembly in the transmission case.





23. Countershaft retainer and shims.





24. Roll pin from forward end of reverse idler shaft.
25. Remove reverse idler shaft, rubber O-ring seal and gear from the transmission case.
26. Rear countershaft bearing race.





27. Countershaft bearing using appropriate pullers.
- Move countershaft assembly rearward, tilt countershaft upward and remove from case.
28. Rear countershaft bearing from shaft using J 37359 with J 22912-01.