New Venture Gear 1500 (RPO MW2) 5-Speed

1. Remove idler shaft support bolts and bottom two bolts. Attach special tools, or equivalents, as follows:

a. Base holding fixture tool No. J3289-20, or equivalent, onto transmission case.






b. Balance bracket tool No. J8763-21 onto holding fixture C-clamp tool No. J8763-02, or equivalents.

c. Transmission adapter tool No. J36824, or equivalent, onto trans- mission case.

d. Holding fixture C-clamp tool No. J8763-02 onto J36824, or equivalents.






2. Remove back-up lamp switch assembly.

3. Remove shift shaft block-out bushing pin.

4. Remove electronic speed sensor assembly.

5. Remove detent plug using detent plug removal tool Nos. J365O9 and J23907 or equivalents.

6. Position transmission vertically with bell housing up.






7, Remove input shaft bearing retainer assembly. Tap clutch release bearing pilot with rubber mallet.

8. Remove snap ring.

9. Position transmission horizontally.






10. Remove nine front housing to rear housing bolts.

11. Drive dowels from front housing and remove front housing.

12. Remove countershaft bearing, then the idler shaft support.






13. Remove shift lever assembly roll pin.

14. Place transmission in neutral, then engage 5th gear.

15. Push shift shaft all the way into housing.

16. Remove shift shaft socket assembly roll pin using suitable 3/16 punch.

17. Remove shift shaft, shift shaft socket, lever and shift shaft block-out bushing.

18. Rotate 3rd-4th shift fork counterclockwise and remove.

19. Install transmission onto assembly pallet tool No. J41663 or equivalent.

20. Remove five bolts on rear of case.

21. Remove tool Nos. J8763-02 and J36824 from housing.

22. Remove rear housing attaching bolts, then the rear housing.






23. Remove output shaft bearing retainer.






24. Remove shift forks.

25. Remove reverse idler gear, countershaft and countershaft bearing.

26. Remove speed sensor rotor using tool Nos. J21427-02 and J8105 or equivalents. Do not reuse rotor after removal.






27. Remove snap ring, bearing assembly and output shaft.

28. Remove mainshaft assembly.

29. Leave synchronizer ring on 3rd-4th synchronizer assembly to prevent detent balls from popping out.

30. Remove input shaft gear and pocket bearing.