Disassemble

1. Remove bell housing-to-transmission case attaching nuts, then the bell housing and gasket.
2. Remove drain plug and drain lubricant from transmission. If necessary, clean metal filings from drain plug and reinstall.
3. Place transmission in neutral, then remove speedometer sleeve and driven gear assembly from extension housing.
4. Remove 3 bolts and 4 nuts securing extension housing to transmission case. Lift control lever to the left and slide rearward, then remove extension housing. Use care to avoid damaging oil seal.
5. Remove control lever and rod through opening in front end of extension housing.
6. Remove back-up lamp switch from extension housing, if necessary.
7. Remove and discard anti-spill seal from mainshaft.

NOTE: A replacement anti-spill seal is not necessary for assembly.

8. Remove speedometer drive gear snap ring, then the drive gear and lock ball.
9. Evenly loosen transmission case cover attaching bolts, then remove the cover and gasket.
10. Mark shift rails and forks for assembly reference, then drive roll pins out of shift rod ends and remove the rod ends.
11. Separate transmission case and bearing housing by prying with a screwdriver, then slide bearing housing off mainshaft.

Mainshaft Rear Bearing Removal:

12. Remove mainshaft rear bearing snap ring and washer, then the rear bearing.

Countershaft Rear Bearing Removal:

13. Remove snap ring from rear end of countershaft, then the countershaft bearing.
14. Remove counter 5th gear and spacer from rear of countershaft.
15. Remove center housing complete with reverse idler gear and 2 spacers from transmission case. Remove cap screw and idler gear shaft from center housing.

Detent Spring & Ball Removal:

16. Remove 3 spring cap bolts, detent springs and balls.
17. Remove 4 blind cover-to-transmission case attaching bolts, then the blind covers and gaskets.

5th-Reverse Shift Fork Removal:

18. Remove 5th-reverse shift fork roll pin, then slide shift fork shaft out of transmission case.
19. Shift transmission into 4th gear, then drive out 3rd-4th shift fork roll pin and slide shift fork shaft out of transmission case.
20. Remove 1st-2nd shift fork roll pin, then slide shift fork shaft out of transmission case.
21. Remove both interlock pins.

5th Gear Removal:

22. Remove 5th gear snap ring, then the thrust washer, lock ball, 5th gear and synchronizer ring from rear of mainshaft.
23. Install tool No. T77J-7025-E between 4th speed synchronizer ring and synchromesh gear on mainshaft and shift transmission into 2nd gear.

Removing Or Installing Locknut:

24. Fold back end of lockwasher, then remove mainshaft locknut.
25. Remove reverse gear and clutch hub assembly from mainshaft and the counter reverse gear from countershaft.
26. Remove mainshaft center bearing cover attaching bolts and the cover.

Countershaft Center Bearing Removal:

Mainshaft Center Bearing Removal:

27. Remove countershaft center bearing, then the mainshaft center bearing.

Positioning Retainer Ring For Removal:

NOTE: It may be necessary to rotate the retainer ring to align the split in ring midway between recessed areas. This will protect the retainer ring during bearing removal.

28. Remove mainshaft rear bearing shim and spacer.
29. Remove 4 front cover-to-case attaching bolts and studs, then the front cover. Remove and retain shim on inside of front cover.

Countershaft Center Bearing Removal:

Positioning Retainer Ring For Removal:

30. Remove input shaft snap ring, then the input shaft bearing in same manner as countershaft center bearing.
31. Rotate both shift forks so main gear train falls to bottom of case, then remove the shift forks.

Positioning Input Shaft Flats:

32. Rotate input shaft so one of two flats on input shaft faces upward.
33. Remove snap ring from front of countershaft.

Countershaft Removal:

34. Install tools as shown in image and press countershaft until it contacts synchronizer ring holder and countershaft spacer.

Countershaft Center Bearing Removal:

Positioning Retainer Ring For Removal:

35. Remove countershaft front bearing in same manner as countershaft center bearing.
36. Remove shim from behind countershaft front bearing.
37. Remove countershaft, then the input shaft from transmission case.
38. Remove synchronizer ring and bearing from mainshaft.
39. Remove mainshaft and gear assembly from transmission case.

Countershaft Bearing Inner Race Removal:

40. Remove countershaft center bearing inner race.
41. Remove 1st gear, 1st-2nd synchronizer ring and snap ring from mainshaft.
42. Install tool No. T71P-4621-8 between 2nd and 3rd gears and press mainshaft out of 3rd gear and 3rd-4th clutch hub sleeve.

Exploded View Of Shafts & Gears:

43. Press 1st-2nd clutch hub and sleeve assembly and 1st gear sleeve from mainshaft.