Warner T5 (77mm) 5-Speed

Fig. 1 (1 of 2):

Fig. 1 (2 of 2):

Except for fill plug and gear shift lever attaching bolts, all threaded holes and bolts used in the model T5 transmission case have metric threads. When using replacement bolts be sure they are the same size and length as originals.

1. Remove drain plug, drain lubricant.






2. Shift transmission into neutral position, then remove control lever and control lever boot.






3. Remove pin from offset lever.

4. Remove extension housing and offset lever from transmission case. The offset lever is engaged into the extension housing and cannot be removed when the extension housing is mounted to the transmission case. A lug, located on the bottom of the offset lever, meshes with the detent plate preventing enough rearward movement of the offset lever to allow removal.






5. Remove offset lever detent ball and spring as shown.

6. Two shift cover bolts are alignment bolts, note their position for installation. Remove transmission shift cover bolts, then using a suitable pry bar break cover to case seal by prying carefully between cover and case.

7. Lift shift cover slightly and slide it to the filler plug side of transmission. When shift mechanism clears groove in fifth/reverse shift lever, continue lifting cover.

8. Support fifth/reverse shift rail assembly with block of wood, then drive out roll pin from fifth gear shift fork with a suitable pin punch and hammer.

9. Using snap ring pliers, remove fifth gear synchronizer snap ring retainer, brake ring and blocking ring from rear of countershaft.






10. Remove fifth gear, synchronizer and shift fork as an assembly.






11. Using long needle nose pliers, remove C-clip retaining fifth/reverse shift lever to lever pivot pin.

12. Remove fifth/reverse shift lever pin. Do not remove shift lever at this time.

13. Remove back-up lamp switch from transmission case.






14. Rotate fifth/reverse shift rail clockwise to disengage ball stud from fifth/ reverse shift lever, then pull fifth/reverse shift rail rearward slightly and rotate shift rail counterclockwise to align ball stud with slot in case, remove shift rail as shown.






15. Scribe alignment marks on bearing retainer as shown.

16. Remove bearing retainer attaching bolts, then using a suitable pry bar, carefully work around the edge to break seal.






17. Remove main drive gear shim pack as shown.






18. Rotate input shaft until cut out on clutching teeth aligns with countershaft, then remove input shaft from transmission case. Do not drop
the 15 roller bearings, thrust bearing or race from rear of input shaft.

19. Remove fourth gear blocking ring from third/fourth synchronizer.

20. Remove output shaft bearing race from rear of case. To partially remove bearing race, pull rearward on output shaft until first gear stops against case. If the race sticks, work the shaft back and forth in the case slightly.

21. Tilt output shaft assembly upward and lift assembly out of transmission case. Note location of fifth/reverse shift lever, reverse shift fork and inhibitor spring prior to removal. Note the rotation action of the inhibitor spring during removal. This information will be necessary during assembly.

22. Remove fifth/reverse shift lever, reverse shift fork and inhibitor spring from case by grasping lever and lifting straight up as an assembly. If case replacement is necessary, remove inhibitor spring anchor pin.






23. Using a suitable pin punch and hammer, remove roll pin from reverse idler shaft.

24. Remove reverse idler shaft by sliding it out of the back of case, then reverse idler gear and overtravel rubber stop (O-ring) from case.

25. Using a hammer and suitable punch or chisel, flatten tabs on countershaft retainer at all four corners, then remove four bolts.

26. Remove countershaft retainer and shim(s), then rear countershaft bearing race from countershaft. If race binds or sticks, work the shaft back and forth in case.






27. Using Puller tool No. J-8433 and Puller Clamp tool No. J22912-01 or equivalents, remove countershaft bearing as shown.

28. Move countershaft rearward through bearing bore, then tilt assembly upward and remove from case.

29. Remove the front countershaft bearing race only if it is worn or damaged. If bearing race removal is necessary, proceed as follows:






a. Install Bearing Race Receiver And Case Support (two pieces) tool No. J-3735S-2 or equivalent, as shown. Failure to support case correctly will result in permanent distortion of case.

b. Using a press, remove front bearing race and O-ring from case.