Shift Cover

Disassembly

Fig. 17 Shift Lever & Components:

1. Remove seven retaining pins using proper size easy outs, Fig. 17.
2. Remove third and fourth shift rail as follows:
a. Note positions of shift forks and rods before removing them.
b. Ensure shift rails are in neutral position.
c. Rotate shift rail until notches are facing upward.
d. Drive rail along notches outward through shift cover, along with expansion plug.
3. Remove shift lug and fork from shift rail.
4. Remove shift rod interlock pin from shift rail.
5. Remove shift interlock plungers, shift fork poppet plunger and shift rod poppet ball spring.
6. Remove first and second shift rail as follows:
a. Rotate shift rail until notches are facing upward.
b. Drive rail along notches outward through shift cover, along with expansion plug.
7. Remove shift lug and fork from shift rail.
8. Remove shift fork poppet plunger and shift rod poppet ball spring.
9. Remove overdrive and reverse shift rail as follows:
a. Rotate shift rail until notches are facing upward.
b. Drive rail along notches outward through shift cover, along with expansion plug.
10. Remove shift lug and fork from shift rail.
11. Remove shift fork poppet plunger and shift rod poppet ball spring.
12. Remove reverse inhibitor bolts and reverse inhibitor.

Inspection
1. Inspect shift forks for damage, bends and worn or damaged fork pads.
2. Inspect shift rails for damage, bends, worn or damaged detents or interlock plungers and worn or broken poppet plungers and springs.
3. Inspect shift cover for cracks, warping and smooth shift rail fit.

Assembly
1. Install reverse inhibitor bolts and reverse inhibitor.
2. Install shift rod poppet ball spring and shift fork poppet plunger.
3. Install overdrive and reverse shift rail into shift cover.
4. Install shift fork and shift lug onto shift rail.
5. Install shift rod poppet ball spring and shift fork poppet plunger.
6. Install first and second shift rail into shift cover.
7. Install shift fork and shift lug onto shift rail.
8. Install shift interlock plungers, shift rod poppet ball spring and shift fork poppet plunger.
9. Install third and fourth shift rail into shift cover.
10. Install shift lug and fork onto shift rail.
11. Drive seven retaining pins into mounting surface with a punch.