Disassembly

Special Tools:

1. Position the transmission on a work bench.





2. Disconnect the (A) HEGO sensor connectors, (B) VSS connector, (C) backup lamp switch connector and remove the (D) wiring harness.





3. Remove the case cover.
1 Remove the bolts.
2 Remove the case cover.





4. Use (A) Seal Remover to remove the (B) extension housing seal.





5. Remove the extension housing.
1 Remove the bolts.
2 Remove the extension housing.





6. Remove the speedometer drive gear.
1 Remove the speedometer gear retaining ring.
2 Remove the speedometer drive gear.





7. Slide the first/second and third/forth synchronizer sleeves forward to lock the transmission into first and third gears.





8. Remove and discard the countershaft locknut.





9. Remove the (A) countershaft rear bearing and (B) the countershaft rear bearing thrust washer.





10. Remove and discard the output shaft rear bearing locknut using a Mainshaft Locknut Wrench.





11. Remove the reverse idler shaft bolt.





12. Remove the reverse idler gear and bushing.





13. Use (A) Remover/Replacer Tube, (B) TOD Forcing Screw and (C) Bearing Puller to remove the (D) output shaft bearing.





14. Remove the output shaft (A) reverse gear and (B) bushing.





15. Remove the output shaft spacer.





16. Remove the (A) countershaft reverse gear, (B) two countershaft reverse gear bearings and (C) the reverse synchronizer blocking ring.





17. Remove the countershaft split washer.





18. Remove the reverse gearshift rail bolt.





19. Remove the fifth/reverse (A) synchronizer, (B) the gear shifter fork and (C) the reverse gear shift rail as an assembly.





20. Remove the countershaft fifth gear.





21. Remove the (A) fifth and reverse shift lever retaining ring and the (B) fifth and reverse shift lever.





22. Remove the lock plate bolt.
- Slide shaft out of case.





23. Remove the countershaft fifth speed gear.





24. Remove the (A) countershaft fifth speed gear split bearing and (B) race.





25. Remove the output shaft fifth speed gear.





26. Remove the rear bearing retainer.
1 Remove the retainer bolts.
2 Remove the rear bearing retainer.





27. Remove the bolts.





28. Remove the front bearing retainer.
1 Install Front Cover Removing Bolt Set into the slave cylinder bolt locations.
2 Remove the front bearing retainer.
- Alternately tighten bolts until bearing retainer can be removed by hand.





29. Remove the (B) fluid baffle, (A) fluid baffle shim and (C) countershaft bearing shim.





30. Remove the fluid passage bolt.





31. Remove the fluid passage.





32. Remove the input shaft front bearing race.





33. Remove the output shaft center bearing race.





34. Separate the (A) input shaft and (B) output shaft.





35. Remove the output shaft.





36. Remove the input shaft.





37. Remove the countershaft.





38. Inspect the countershaft for damage.