a. Transmission Disassemble
- Tools Required- J 22912-01 Bearing and Gear Puller
- J 8433 Pulley Puller
- J 8433-1 Puller Bar
- J 3289-20 Bench Fixture
- J 36842 Holding Fixture
- J 39431-1 Rear Remover and Bolts
1. Clean the exterior of the transmission assembly with solvent.
2. Install the J 36842 onto the transmission.
3. Mount the transmission on a workbench. Using the J 3289-20.
4. Remove the transmission oil drain plug.
5. Drain the transmission fluid into a suitable container.
6. Remove the shifter bolts and the shifter.
7. Remove the vent pipe bracket bolt.
Important: position the offset lever in neutral (centered). This will avoid driving the roll pin into the detent plate making further disassembly extremely difficult. Do not 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. The lug prevents moving the lever far enough for removal.
8. Drive out the roll pin from the offset lever.
9. Remove the extension housing-to-transmission case bolts.
10. Remove the housing and the offset lever as an assembly.
11. Remove the detent ball and spring from the offset lever.
12. Remove the roll pin from the extension housing or from the offset lever.
13. Remove the oiling funnel from the rear of the countershaft.
14. Remove the bolts attaching the transmission case cover and the shift fork assembly to the case. Note the location of these bolts for assembly reference. Two of the cover bolts are alignment-type dowel bolts.
15. Remove the case cover.
16. Remove the following parts:
16.1. The reverse lever spring clip
16.2. The pivot bolt
17. Remove the backup lamp switch.
18. Remove the 5th speed gear synchronizer retainer ring and the retainer from the rear of the countershaft.
19. Unhook the reverse lock spring from the side of the transmission case.
20. Remove the following parts as an assembly:
20.1. The 5th speed gear
20.2. The synchronizer
20.3. The shift fork
20.4. The shift rail (If necessary, rotate the shift rail in order to disengage the shift rail from the reverse [ever assembly.)
21. Remove the retainer ring from the mainshaft.
22. Remove the speedometer reluctor wheel retainer ring.
23. Remove the speedometer reluctor wheel and the reluctor wheel retainer ball using the J 8433-1 and the J 39431-1.
24. Remove the retainer ring from the 5th speed driven gear.
25. Remove the following parts in order:
25.1. The front bearing retainer bolts
25.2. The front bearing retainer
25.3. The front bearing race
25.4. The end play shims
26. Remove the main drive gear from the transmission case. Rotate the main drive gear until the flat surface faces the countershaft. Do not to drop the 15 roller bearings, the thrust bearing, or the bearing race from the main drive gear.
27. Remove the 4th speed gear blocker ring from the 3rd/4th speed gear synchronizer.
28. Remove the mainshaft rear bearing race. If the bearing race sticks, the bearing race is probably misaligned in the case bore. Move the mainshaft back and fourth in order to loosen the bearing race.
29. Remove the mainshaft from the transmission case.
30. Remove the reverse gear fork assembly from the transmission case.
31. Bend the locking tabs away from the countershaft retainer bolts.
32. Remove the following parts:
32.1. The countershaft retainer bolts
32.2. The countershaft retainer
32.3. The shims
33. Drive the roll pin out of the forward end of the reverse idler shaft.
34. Remove the following parts in order:
34.1. The reverse idler gear shaft
34.2. The rubber O-ring seal
34.3. The reverse idler gear
35. Remove the rear countershaft bearing race.
36. Remove the countershaft bearing. Using the J 8433 and the J 22912-01.
37. Remove the countershaft from the transmission case.