Transmission Disassembly

- Tools Required:
- J 3289-20 Base Holding Fixture
- J 8763-02 Holding Fixture C-Clamp
- J 8763-21 Balance Bracket for C-Clamp
- J 36824 Transmission Adapters
- J 36509 Detent Sprint Plug Remover
- J 23907 Slide Hammer
- J 36515 Assembly Pallet
- J 36515-15 Mainshaft Adapter
- J 36515-16 Countershaft Adapter
- J 24420-B Gear Puller
- J 21427-01 Speedometer Gear Puller Adapter
- J 26941 Output Shaft Oil Seal Remover














DISASSEMBLE





1. Idler shaft support bolts and bottom two bolts.





- J 8763-21 onto J 8763-02.
- J 36824 onto the transmission case.
- J 8763-02 onto J 36824.





2. Backup lamp switch assembly.
3. Shin block-out bushing pin.
4. Bolt and electronic speed sensor assembly.
5. Detent plug using J 36509 and J 23907, spring, and plunger.
6. Position transmission vertically.





7. Six bolts and input shaft bearing retainer assembly.
A. Tap clutch release bearing pilot with a rubber mallet.
8. Snap ring.
9. Position transmission horizontally.





10. Front housing to rear housing bolts.
11. Drive dowels into front housing.
12. Front housing.
13. Countershaft bearing.
14. Idler shaft support.
- Snap out.
- Be careful not to loose shift lever detent plunger and spring.
15. Move all shift forks forward to engage fourth, second, and reverse gears.
16. Roll pin.

Important
A. Rotate shift finger down.
B. Support the shift shaft end while driving out lever roll pin.
C. Allow roll pin to clear second gear.

17. Place all gears in neutral. Then engage fifth gear.
18. Push shift shaft all the way into the housing.
19. Shift shaft socket assembly roll pin.
- Rotate input shaft until gap in the fifth/reverse synchronizer hub is directly under the roll pin.
- Support the shift shaft end.
- Drive shift socket pin down using a 5 mm (3/16 inch) punch.
- Pin will fall into the case.

NOTICE: Excessive force will "peen" the shift shaft and damage the rear housing shift shaft bearing causing Increased shift effort.

20. Shift shaft, shift shaft socket assembly, lever, and shift shaft block out bushing.
21. Rotate third-fourth shift fork counterclockwise and remove.
22. Four bolts securing the shift lever housing to the transmission.

Important
- Do not disassemble the transmission shift lever housing.
- Refer to "Shin Lever Housing" for additional information about removing the shift lever housing.

23. Loosen, but do not remove, 3 bolts on the rear of case.





24. Install J 36515-15 and J 36515-16 onto the input and Countershaft Install J 36515 to the transmission assembly.
25. J 8763-02 and J 36824 from the housing.
26. Bolts from the rear housing.





27. Tap housing with a rubber mallet and remove rear housing from assembly.





28. Output shaft bearing retainer.





29. Shift forks.
30. Reverse idler gear.
31. Countershaft.
32. Countershaft bearing.





33. Speed sensor rotor using J 21427-01 and J 24420-B.
- Do NOT reuse rotor after removal.





34. Snap ring.
35. Bearing assembly, output shaft.
36. Mainshaft assembly.

Important
- Leave the synchronizer ring on the third-fourth synchronizer assembly to prevent the synchronizer detent balls from popping out.

39. Input shaft gear and pilot bearing.