13. Extension Disassemble

Extension Disassemble

Special Tools
* DT 49216 - Shift Rail Bearing Remover
* J 23907 - Slide Hammer with Bearing Adapter
* J 26941 - Bearing Race Remover
* J 29369-2 - Bushing and Bearing Remover - 2-3 in
* J 36190 - Universal Driver Handle
* J 39431 - Fifth/Sixth Driven Gear Puller
* J 39439-1 - Bushing Installer
* J 39439-2 - Shift Rail Bushing Remover
* J 39439-3 - Bushing Installer
* J 45124 - Removal Bridge
* J 45124-9 - Puller Leg

For equivalent regional tools, refer to Special Tools Special Tools and Equipment.




1. Remove the reverse idler shaft bracket bolts and bracket.




2. Remove the reverse idler gear and the roller bearing.




3. Remove the reverse idler gear shaft (1).




4. Remove the countershaft rear bearing retainer (1).

Note: The plastic roller bearing cage (2) and bearings are part of the countershaft bearing assembly. Always use a new countershaft bearing assembly.

5. Cut away the plastic roller bearing cage (2) from the countershaft bearing assembly.
6. Remove the bearings (3). Discard the cage and bearings.




7. Install J 45124-1 - removal bridge (1), J 45124-9 - puller leg (2), and J 29369-2 - remover (3) in the race from the countershaft bearing assembly in the extension housing.
8. Remove the race.





Note: The bearing race is part of the countershaft bearing assembly. Always use a new countershaft bearing assembly.

9. Remove the oil funnel (1) from the bearing race (2). Discard the bearing race.




10. Using J 39439-2 - remover (2) and J 23907 - slide hammer (1), remove the bushing.




11. Remove the output shaft seal (1).
Pry out the seal with a suitable tool.




12. Remove the snap ring (1) and the roller bearing (2).




13. Remove the mounting bolt, the reverse lockout assembly (1) and the O-ring.




14. Remove the bolt and the vehicle speed sensor (1).
15. Remove the plug (2).




16. Remove the mainshaft bearing race retainer ring (1).





Note: Do not replace the bearing race unless inspection shows bearing race damage.

17. Place the extension housing on a flat work surface. Locate the oil clearance gap between the housing and the main shaft bearing race.
18. Insert a brass drift (1) through the mainshaft opening of the extension housing, into the oil clearance gap. Using a mallet, tap down on the drift to remove the mainshaft bearing race (2).




19. Remove the reverse rail bushing using the J 36190 - handle (1) and J 39439-2 - installer (2).




20. Remove the rear housing shift rail seal (1).




21. Remove the shift rail bearing using the J 23907 - slide hammer (1) and DT 49216 - remover (2).