1. Transmission Disassemble

Transmission Disassemble

^ Tools Required
- J 8614-01 Flange and Pulley Holding Tool
- J 22912-01 Split-Plate Bearing Puller
- J 38805 Output Shaft Nut Socket - 4WD only
- J 44707 T-Bar Push Puller
- J 45545 Adapter 3/8 inch NF to 5/8 inch NF





Important: In order to remove the shift tower, the transmission must be in neutral.

1. Shift the transmission to neutral.
2. Remove the bolts that secure the shift lever to the transmission.
3. Remove the shift lever and shift tower spacer.





Important: Note the location of the brackets on the shift cover bolts in order to reinstall them in the correct location.

4. Remove the bolts that secure the shift cover to the transmission.
5. Using screwdrivers in the transmission case slots, pry the shift cover from the transmission.





6. Using the J 8614-01 to hold the propeller shaft yoke, loosen the mainshaft nut.





7. For C model, remove the following parts:
1. The mainshaft nut
2. The washer and discard
3. The rubber washer and discard
4. The yoke assembly





8. For C model, remove the vehicle speed sensor and the O-ring seal.





9. For K model, remove the transmission extension bolts.
1. Remove the transmission extension.





11. For C model, remove the transmission extension bolts.
12. Remove the transmission extension.





13. For K model, using the J 38805 (1), remove the mainshaft nut and washer.
14. Discard the washer.





Important: Use the correct size punch when removing the shift fork roll pins. If the punch is too large, it may flare the shaft rail and cause hard removal of the shift fork.

15. Remove the overdrive gear shift fork roll pins.





16. Remove the overdrive gear retainer ring.





Important: For installation alignment, scribe an alignment mark on the synchronizer hubs and synchronizer sleeves before removing. To prevent the synchronizer springs and struts from being lost, do not separate the synchronizer hubs from the synchronizer sleeves. Keep the synchronizer clutch gear and the blocking rings with the synchronizer hubs. Organize the components in order to install the components in their original location and position.

17. Scribe a mark on the overdrive synchronizer hub and synchronizer hub sleeve.





18. Remove the overdrive gear assembly, with the shift fork, from the countershaft.
19. Remove the roller bearing.





20. Remove the thrust washer.
21. Remove the thrust washer pin from the countershaft.





Important: Only remove the vehicle speed sensor during this procedure.

22. For C model, remove the vehicle speed sensor reluctor using J 44707 (1), J 45545 (2) and J 22912-01 (3) or equivalent.



23. For C model, remove the mainshaft overdrive gear using J 44707 (1), J 45545 (2) and J 22912-01 (3), or equivalent.





24. Remove the mainshaft rear bearing retainer bolts.
25. Remove the mainshaft rear bearing retainer.
26. Remove the shim or shims.
27. Remove the mainshaft rear bearing cup.
28. Move the synchronizer sleeves into the neutral position.
29. Position the overdrive gear shift lever over to the side and hold in position with a rubber band.





30. For installation alignment, mark the input shaft bearing retainer to the transmission case.
31. Remove the input shaft bearing retainer bolts.
32. Remove the input shaft retainer.





33. Remove the input shaft.
34. Remove the main drive gear bearing.





35. Use the following procedure in order to remove the mainshaft assembly from the case:
1. Lift the mainshaft and move to the rear of the case.
2. Tip the front of the mainshaft up and remove the mainshaft from the case.





36. Remove the countershaft bearing retainer bolts.
37. Remove the countershaft bearing retainer.
38. Remove the shim or shims.
39. Remove the countershaft rear bearing cup.





40. Remove the reverse idler gear and shaft:
1. Using a suitable punch, drive the reverse idler gear shaft towards the rear of the case.
2. Remove the reverse idler gear.
3. Remove the thrust washers.
4. Remove the bearing.





41. Remove the countershaft rear bearing using J 44707 (1), J 45545 (2) and J 22912-01 (3), or equivalent. Removing the countershaft rear bearing will allow the countershaft to be angled for removal.





42. Remove the countershaft from the transmission case. Slide the countershaft rearward and lift the front of the countershaft out of the case.





43. Using a punch or chisel, remove the countershaft front bearing cap.
44. Discard the removed bearing cap.
45. Remove the countershaft front bearing cup.





46. Remove the roll pin from the overdrive gear shift lever.
47. Remove the shift lever shaft.
48. Remove the overdrive gear shift lever.