Case: Service and Repair

UNDER 8500 GVW - WITH M5OD, 5-SPEED

DISASSEMBLE

Removing Dust Cover:

1. Place top cover in a suitable holding fixture.
2. If necessary, remove dust boot, then lift shift lever from top cover.
3. Remove three dust cover retaining screws, then the dust cover. To facilitate installation, note grooves in bushings aligned with slots in lower shift lever faces toward front of transmission.
4. Invert top cover on holding fixture, then remove back-up lamp switch and back-up lamp switch pin.

Removing Shift Forks:

5. Remove spring pins retaining shift forks to shift rails, then discard spring pins.
6. Ensure 5th/reverse shift rail is in full forward position, then remove spring pin from end of 5th/reverse rail.

Cross-sectional View Of Shift Rail Assembly:

7. Remove three rubber plugs blocking shift rod service bores.

CAUTION: To prevent component loss when performing the following procedures, cover lock balls, friction device, and spring seats with a suitable clean cloth held firmly in place. Wear safety glasses during shift rail removal.

8. Remove 5th/reverse shift rail from top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining rearward pressure.
9. Remove 3rd/4th shift rail from top cover through service bore. If necessary, insert a suitable drift through spring pin bore and gently rock shift rail from side to side while maintaining rearward pressure.

Removing 5th/Reverse Cam Lockout Plate:

10. Remove 5th/reverse cam lockout plate retaining bolts, then the 5th/reverse cam lockout plate.

ASSEMBLE
1. Place top cover in a suitable holding fixture.
2. Position 5th/reverse cam lockout plate to top cover. Install 5th/reverse cam lockout plate retaining bolts, then torque to 6-7 ft lbs.
3. Position 3rd/4th shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure.
4. Engage 3rd/4th shift fork with shift rail, then position detent ball and spring into top cover spring seats.
5. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball.
6. Position friction device and spring into top cover spring seats.
7. Compress friction device and spring assembly, using a suitable tool, then push shift rail into position over friction device.
8. Install 3rd/4th shift fork to shift rail retaining spring.
9. Position 1st/2nd shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure.
10. Engage 1st/2nd shift fork with shift rail, then position detent ball and spring into top cover spring seats.
11. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball.
12. Position friction device and spring into top cover spring seats.
13. Compress friction device and spring assembly, using a suitable tool, then push shift rail into position over friction device.
14. Install 1st/2nd shift fork to shift rail retaining spring.
15. Position 5th/reverse shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure.
16. Engage 5th/reverse shift fork with shift rail, then position detent ball and spring into spring seats.
17. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball.
18. Install shift rail to top cover spring pins, then the 5th/reverse shift fork to shift rail retaining spring pin.
19. Install rubber plugs into service bores.
20. Insert interlock pins into 1st/2nd and 3rd/4th shift rails. Ensure large and small interlock pins are installed into their original positions. Improper installation of interlock pins will prevent activation of neutral switch and/or back-up lamp switch.
21. Apply a suitable sealant to back-up lamp switch and neutral switch threads. Install switches in top cover, then torque to 18-26 ft lbs.
22. Position lower shift lever and dust cover assembly into top cover, then install three retaining screws and torque to specifications.