Disassembly

NV5600 Transmission

DISASSEMBLY





NOTE: Use Fixture 8241 for moving and handling the transmission. The fixture supports the transmission at the center of gravity in order to ease mounting the transmission into the build fixture.

1. Mount transmission (2) into Fixture 8230 (1).
2. Rotate transmission to a horizontal position.





3. Remove shift tower (1) from transmission (2).





4. Remove isolator plate (1) from transmission (2) .





5. Remove primary shift rail detent plug (1).





6. Remove primary shift rail detent spring (1).





7. Remove primary shift rail detent plunger (1).





8. Remove clutch housing bolts (1) from inside the housing.





9. Remove shift rail blocker bolt (1) from transmission case.

EXTENSION/ADAPTER HOUSING





1. Remove extension/adapter housing bolts from transmission case.
2. Remove extension/adapter housing (2) from the transmission gear case with Puller 8244 (1).

NOTE: Keep housing straight during removal due to reverse idler shaft may bind on one side of the housing.





3. Remove crossover detent plug (1), spring and plunger from the extension/adapter housing (2).





4. Remove bolt (2) and washer holding the crossover cam (1) to the extension/adapter housing (3).
5. Remove crossover cam from extension/adapter housing.
6. Remove back-up lamp switch from extension/ adapter housing.





7. Remove countershaft rear bearing race from extension/adapter housing with Remover L-4518 (1).





NOTE: Tag all countershaft pre-load shims (1) from between the bearing race (2) and the housing.

8. Remove crossover cam bushing from the extension/adapter housing with Remover 8240.
9. On 4X2 vehicles, remove extension housing seal with a pry tool or a slide hammer and screw.
10. On 4X4 vehicles, remove adapter housing seal with a pry tool or a slide hammer and screw.

TRANSMISSION GEAR CASE





1. Remove remaining bolts from transmission case to the clutch housing.
2. Remove shift socket roll pin with a 6 mm (7/32 inch) punch and hammer.
3. Turn shift socket so it won't catch the case when lifting it up.
4. Install Fixture 8232 (1) to the transmission case (2).
5. Attach an engine crane or equivalent to Fixture 8232 and remove the transmission gear case from the clutch housing.
6. Remove rear output shaft and countershaft bearing races from the transmission gear case with a brass drift and hammer.

GEARTRAIN





1. Remove 5-6 crossover bracket (1) bolts.





2. Mount Fixture 8232 (2) to output shaft (1) and countershaft.
3. Attach engine crane to Fixture 8232 and raise geartrain approximately � inch from the clutch housing.
4. Remove 5-6 crossover bracket from the clutch housing.
5. Lower geartrain back into the clutch housing.





6. Install Holding Tool 8242 (1) onto 5-6 synchro (2) and tighten screw to hold 5-6 synchro together during removal.

NOTE: Note the order of the shift fork arms at the primary shift rail, while in the Neutral position.





7. Raise geartrain and shift rails until all the shift rails clear the clutch housing.
8. Remove shift rails (1) from the rest of the geartrain.
9. Raise geartrain until the input shaft is clear of the clutch housing.





10. Remove geartrain from clutch housing and install geartrain into Support Stand 8246 (2).
11. Remove Fixture 8232 (1) from output shaft and countershaft.
12. Separate countershaft from output shaft.
13. Separate output shaft from the input shaft. Hold 5-6 synchro together while removing output shaft to prevent synchro sleeve from being dislodged from the synchro hub.

COUNTERSHAFT BEARINGS





1. Remove snap-ring holding the front countershaft bearing onto the countershaft.
2. Remove front countershaft bearing with Collar 6444-8, Jaws 6451 (2), Puller Rods 6444-4 and Puller 6444 (1).





3. Remove rear countershaft bearing with Collar 6444-8, Jaws 6447 (2), Puller Rods 6444-4, Puller 6444 (1) and suitable press button.

OUTPUT SHAFT BEARINGS





1. Remove snap-ring holding the pocket bearing onto the output shaft.
2. Remove pocket bearing from the output shaft with Sleeve 6444-8, Jaws 8234 (2), Puller Rods 6444-4 and the remainder of Puller 6444 (1).
3. Remove snap-ring holding the rear output shaft bearing onto the output shaft.
4. Use Collar 6444-8, Jaws 8271 and Puller Rods 6444-3 for 4X2 vehicles or Puller Rods 6444-4 for 4X4 vehicles with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft.
5. Remove rear output shaft thrust washer from the output shaft.

INPUT SHAFT





1. Remove fifth gear blocker ring (1) from the input shaft (2).





2. Remove fifth gear friction cone (1) from the input shaft (2).





3. Remove output shaft bearing race from the input shaft (2) with Puller L-4518 (1).





4. Remove input shaft bearing and oil guide from the input shaft with Collar 6444-8, Jaws 8243 (2), Puller Rods 6444-6 and the remainder of Puller 6444 (1).

OUTPUT SHAFT





NOTE: Some gear and synchro components can be installed backwards. Mark the gears, clutch gears, synchro hubs, and sleeves for installation reference during disassembly. Use paint or a scribe for marking purposes. Then stack the geartrain parts in order of removal.

1. Remove first gear from the output shaft.
2. Remove first gear bearing (2) from the output shaft (1).





3. Remove first gear blocker rings (2) and cone (3) from the 1-2 synchro assembly.
4. Install the remainder of the output shaft into Fixture 8227 with press blocks under second gear.





5. Install shaft and Fixture assembly into a shop press.
6. Press second gear (3), 1-2 synchro assembly (5) and first gear bearing sleeve (2) from the output shaft (1)
7. Remove second gear bearing from the output shaft.
8. Reverse output shaft in the Fixture 8227 with press blocks positioned under the 5-6 synchro assembly.
9. Press the 5-6 synchro assembly from the output shaft.





10. Remove sixth gear (2) and the sixth gear bearing from the output shaft (3).

COUNTERSHAFT





1. Install the countershaft into Fixture 8227 (3) with press blocks located under the fifth countershaft gear (2)
2. Place the assembly into a shop press.
3. Use Guide 8235 (1) on end of countershaft and press the countershaft fifth gear from the countershaft.





4. Place countershaft in Fixture 8227 (3) with press blocks placed under the sixth countershaft gear (2).
5. Use Guide 8235 (1) on end of countershaft and press the countershaft sixth gear from the countershaft.
6. Remove countershaft from the press and Fixture 8227.





7. Remove fourth countershaft gear (5), friction cone (4), blocker ring (1) and bearing (2) from the countershaft (3).





8. Install countershaft (5) into Fixture 8227 (2) with press blocks located under the third countershaft gear (1)
9. Place assembly into a shop press and press third countershaft gear, 3-4 synchro (3) and fourth countershaft gear bearing sleeve (4) from the countershaft.
10. Remove countershaft from the press and Fixture 8227.





11. Remove third countershaft gear bearing (3) from the countershaft (1).
12. The 2-3 thrust washer (2) should not normally need to be removed from the countershaft. If necessary slide 2-3 thrust washer off countershaft.

CLUTCH HOUSING





1. Remove input shaft retainer (1) bolts from the clutch housing (2) and remove retainer.





2. Remove countershaft oil guide (2) from the countershaft front bearing bore in the clutch housing (1).





3. Remove countershaft front bearing race, endplay shims and spacer from clutch housing (1) with Remover 6061-1 (3) and Handle C-4171 (2).
4. Remove input shaft bearing race with Remover/Installer 8237 and Handle C-4171.





5. Remove input shaft oil guide (1) and retainer seal (2).