Disassembling M45
2520 Stand:
1. Attach fixture P/N 5130. Use four bolts to attach to stand P/N 2520.
NOTE: Modified type fixture P/N 5130 must be used. Refer to "Modification Of Fixture P/N 5130". Tools and Equipment
2. Install transmission fixture. Ensure all mating surfaces align when tightening holding bolt.
3. Remove sound deadening material from gearshift carrier. Remove drain plug and drain oil.
4. Remove:
- Back-up light switch.
- Transmission top cover.
5. Remove:
- Spring and detent ball.
- Selector plate assembly and return spring.
- Gasket.
6. Remove:
- Glide washers for selector plate assembly.
- Lock pin for shifter.
7. Remove:
- Selector rail.
- Shifter and shift forks.
8. Remove gearshift carrier assembly.
9. Remove drive flange nut, use 27 mm (1-1/16 in) socket. Use wrench P/N 5149 to hold flange.
10. Pull off drive flange. Use puller P/N 2261.
12. Remove speedometer driven gear. Remove bolt and retainer to pull out gear.
13. Remove rear cover. Remove gasket and shims.
14. Remove speedometer drive gear.
15. Remove main shaft bearing. Position adapter P/N 2985 between input shaft and front synchro ring. Remove bearing spacer ring. Use tools P/N 5058 and 5147 to pull off bearing. Remove thrust washer.
16. Remove clutch fork. Save spacer washer and throw-out bearing.
17. Remove bell housing. Remove gasket and shims. Use inhex wrench 8 mm.
18. Remove outer races for intermediate shaft bearings:
^ CAST IRON housing. First knock intermediate shaft back until rear race is free. Then knock intermediate shaft forward until front outer race can be removed
^ ALUMINUM housing. Carefully knock intermediate shaft until puller P/N 5177 can grip races.
19. Pull out input shaft. Remove 4th gear synchro ring.
20. Lift out main shaft.
21. Lift out intermediate shaft.
22. Remove reverse gear and shaft. Use punch to knock shaft back.
23. Remove reverse gear shift fork.
24. Remove seal for selector rail.
5131 Puller:
25. Remove intermediate shaft bearings. Use puller P/N 5131.
26. Remove 1st gear and synchro ring from main shaft.
27. Remove lock ring for 1-2 synchro hub.
28. Press off synchro hub and gear.
NOTE: Can be tight so a press may be needed. Use adapter P/N 2853.
29. Remove lock ring for 3-4 synchro hub.
30. Press off synchro hub and gear.
NOTE: Can be tight so a press may be needed. Use adapter P/N 2853.
31. Remove lock ring and spacer ring for input shaft bearing.
32. Remove input shaft bearing.
NOTE: Can be tight so a press may be needed. Use adapter P/N 2853, small hole UP under bearing.
33. Remove sleeve on gearshift rod joint.
34. Disassemble gear selector rail and gearshift rod. Use a 5 mm punch to push out front pin.
35. Remove gearshift rod bushings.
36. Remove bell housing seal.
2413 Drift:
37. Remove rear cover seal. Use drift P/N 2413 to knock out seal.
38. Disconnect two synchro hubs. Push hubs out of sleeves.
39. Clean all parts in solvent. Blow clean with compressed air.
40. Carefully check all parts. Replace worn or damaged parts. Replace gaskets and seals.