Disassembly

DISASSEMBLY




1. Set transmission on rear housing.
2. Remove shift tower bolts (1) and shift tower (2).




3. Pry off shift tower boot (1) with a screw driver (2).




4. On 4x2 transmissions shift two shift rails to lock the transmission in two gears. Then remove output shaft flange (1) bolt (2). Remove flange from output shaft with a two jaw puller if necessary.




5. Through shift tower opening (1) align shift rails in neutral position (2) and install tie strap to shift rails.




6. Remove 5-6 shift fork pivot pin (1) from both sides of the case.




7. Remove reverse idler gear shaft pin (1) from the rear housing (2).




8. Remove back-up lamp switch (1) bolt (2) and remove switch.




9. Remove transmission housing bolts.
10. Tap housing with dead-blow hammer and lift front housing (1) off rear housing (2).




11. Remove 5-6 shift fork (1) from shift rail and synchronizer sleeve (2).




12. Remove input shaft (1) from mainshaft (2).




13. Thread a M6x1bolt (1) into the reverse idler gear shaft (2) and pull shaft out of rear housing.




14. Slide reverse idler gear (1) off to the side of the case (2) for disassembly clearance.




15. Lift and tilt countershaft (1) then remove mainshaft with shift rails (2).
16. Remove countershaft.




17. Remove reverse idler gear (1) from rear housing (2).

MAINSHAFT





1. Remove reverse (1) 1-2 (2) and 3-4 (3) shift forks and shift rails as an assembly from mainshaft.




2. Position mainshaft in Fixture 9605 mounted in a vise with sixth gear up.
3. Remove fifth gear synchronizer rings (1) from 5-6 synchronizer hub (2).




4. Slowly pull 5-6 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).




5. Remove 5-6 synchronizer sleeve (1) from hub (2).




6. Remove mainshaft bearing (1) snap ring (2).




7. Remove mainshaft bearing (1), 5-6 synchronizer hub (2), and sixth gear synchronizer rings (3) with three jaw puller (4). Position puller jaws under sixth gear synchronizer rings (3).




8. Remove sixth gear (1) and bearing (2) from mainshaft (3).




9. Remove fourth gear (1) snap ring (2).




10. Remove fourth gear thrust washer (1) with Puller 9594. Position puller under fourth gear synchronizer stop ring (2).




11. Install Bridge 938 (1) into Puller 9594 (2) and remove fourth gear thrust washer (3).




12. Remove fourth gear (1) and bearing (2).




13. Remove fourth gear synchronizer rings (1) from 3-4 synchronizer hub (2) and mark installation reference.




14. Slowly pull 3-4 synchronizer sleeve (1) up on hub enough to remove detents and springs (2).
15. Remove 3-4 synchronizer sleeve (1) from hub.




16. Remove 3-4 synchronizer hub (1) snap ring (2).




17. Remove 3-4 synchronizer hub (1) and third gear synchronizer rings (2). Mark components for installation reference.




18. Remove third gear (1) and bearing (2).




19. Turn mainshaft and Fixture 9605 and secured in vise.
20. Remove 4x4 mainshaft snap ring.
21. Remove reverse gear synchronizer sleeve (1) from reverse gear (2) synchronizer hub.




22. Remove reverse gear synchronizer hub (1) detents (2).




23. Remove mainshaft bearing (1) with Bridge 938 (2) and bearing Puller 9647 (3).




24. Position puller (1) behind reverse synchronizer hub and outer blocker ring (2).




25. Remove reverse gear (1) and bearing (2).




26. Remove reverse gear bearing race (1) and thrust washer (2). Use Puller 9646 and Bridge 938 on first gear (3) to pull off reverse gear bearing race (1) and thrust washer (2).




27. Remove first gear (1) and bearing (2).




28. Remove first gear synchronizer rings (1) from 1-2 synchronizer hub (2) and mark for installation reference.




29. Slowly pull 1-2 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).




30. Remove 1-2 synchronizer hub (1) snap ring (2) and remove hub with second gear synchronizer rings. Mark components for installation reference.




31. Remove second gear (1) from mainshaft (2).




32. Remove second gear bearing (1) from mainshaft (2).

COUNTERSHAFT






NOTE: Bearings are the only component serviced on the countershaft.

1. Remove countershaft rear housing bearing with Puller 6444 (1), Plug 8513A (2), Puller Jaws 9597 (3), Puller Collar 6444-8 (4), Puller Rods 6444-3 and Puller Flange 6444-1. Position Puller Jaws 9597 around bearing and puller flange. Position puller collar around the puller jaws. Tighten the puller bolt and remove countershaft bearing.
2. Remove countershaft first/reverse gear bearing oil slinger from countershaft.




3. Remove countershaft front housing bearing with Puller 6444 (1), Puller Collar 6444-8 (2), Puller Jaws 9597 (3), Puller Rods 6444-3 and Puller Flange 6444-1. Position puller jaws around bearing and puller flange. Position puller collar around the puller jaws. Tighten the puller bolt and remove countershaft bearing.

INPUT SHAFT





1. Position input shaft (1) mainshaft bearing seal (2) in a vice then twist input shaft (1) out of the seal (2).




2. Remove input shaft (1) bearing with Puller C-293-PA (2) and Adapters C-293-47 (3).
3. Remove input shaft mainshaft bearing gasket.

REAR HOUSING





1. Remove countershaft bearing cup and mainshaft bearing cup with Puller 9593 (1) installed in cup (2).




2. Install Remover 8915 (1) on puller (2) and tighten remover nut (3) to pull cups out of the housing.




3. Remove output shaft seal (1) from housing (2) with seal pick.

FRONT HOUSING





1. Remove countershaft bearing cup and mainshaft bearing cup with Puller 9593 (1) installed in cup (2).




2. Install Remover 8915 (1) on puller (2) and tighten remover nut (3) to pull cups out of the housing. Then remove end-play shims from bearing bores and oil supply washer from mainshaft bearing bore.




3. Remove input shaft retainer (1) bolts (2) and remove retainer.




4. Remove input shaft seal (1) from retainer bore (2) with a seal pick.