Disassembly

1. Remove three lock ball plugs from intermediate plate.





2. Remove three lock ball springs and lock balls from intermediate plate with pencil magnet.
3. Mount intermediate plate and gear-train assembly in vise as follows:





a. Insert two spare bolts in one bottom bolt hole in intermediate plate. Insert bolts from opposite sides of plates.
b. Install enough flat washers under each bolt head to prevent bolts from touching.
c. Tape bolts and washers in place and mount intermediate plate in vise.
d. Clamp vise jaws securely against bolt heads. Do not clamp vise jaws on intermediate plate. Clamp only on bolt heads.





4. Remove fifth gear snap ring. Retain snap ring for assembly reference. It is a select fit component.





5. Remove E-ring that secures reverse shift arm to fork.





6. Remove bolts attaching reverse shift arm bracket to intermediate plate. Then remove bracket.





7. Remove reverse shift arm and shoe.





8. Remove fifth gear shift fork set screw.
9. Move fifth gear shift rail forward until it clears shift fork.





10. Remove fifth gear shift fork from synchro sleeve.





11. Remove reverse shift rail and reverse shift head as assembly.
12. Measure thrust clearance between counter fifth gear and thrust ring with feeler gauge. Clearance should be 0.10 to 0.40 mm (0.003 to 0.019 inch). If clearance exceeds limits, gear and/or ring will have to be replaced.





13. Loosen fifth spline gear with standard two-jaw puller. Position puller jaws behind fifth counter gear as shown.





14. Remove fifth saline near





15. Remove fifth gear synchro ring.





16. Remove fifth gear synchro and sleeve assembly.





17. Remove counter fifth gear thrust ring.





18. Remove thrust ring lock ball with pencil magnet.





19. Remove bolts attaching output shaft rear bearing retainer to intermediate plate.





20. Remove rear bearing retainer.





21. Remove reverse gear and shaft.