Disassembly

Special Tools:

1. Position the transmission in the Bench Mounted Holding Fixture in a vertical position with the transmission pointing downward.
2. Remove any power take off equipment (if equipped).

3. CAUTION: To prevent damage, do not completely remove the companion Range locknut or the companion flange at this time.

Use the Companion Flange Holding Tool and the Locknut Socket to loosen the companion flange locknut.

4. Remove 15 extension housing-to-case bolts. Leave two bolts installed at opposite sides of the extension housing.

5. Remove the gear selector interlock sleeve and the shifter interlock spring.

6. WARNING: Detent spring plug is under spring pressure. Always wear protective eyeglasses when performing this procedure to make sure that detent spring plug does not strike eyes when it is forced out by spring pressure.

NOTE: The latest detent spring plugs are of a larger diameter than on older vehicles and will not work on older vehicles.

Use the Jet Plug Remover to remove the three detent spring plugs and springs. Discard the detent spring plugs.

7. Remove the reverse idler gear shaft bolts.

8. Remove the backup lamp switch.

9. Remove the two dowel pins.
10. Remove the two extension housing-to-case bolts.

11. CAUTION: The mating surfaces of the case and the extension housing are coated with an adhesive sealing agent. If it is difficult to separate the case and the extension housing because of this adhesive, carefully tap the front of the case with a soft hammer until the bond is loosened. Never use a prying device, such as a screwdriver or chisel, to force case and extension housing apart. This could damage the surfaces and cause leaks.

Carefully lift the case off the extension housing. It may be necessary to push the main gear shift rail inwards to prevent it from hanging up on the case as it is being removed. Use care to make sure that the main gear shift rail is not lifted off together with the case.

12. Remove the main gear shift rail and the shift finger.

13. Remove the reverse idler gear shaft and reverse idler gear.
1 Remove the reverse idler gear shaft.
2 Remove the reverse idler gear and the two reverse idler gear bearings.

14. Remove the selector plate bolts.

15. Position the gear pack holding fixture using an endless lifting sling. Pass the sling over the shift rails.

16. Place the shift rail support over the ends of the shift rails.

17. Rotate the transmission and gear pack holding fixture into a horizontal position while holding the holding fixture beneath the gear pack.

18. Remove the companion flange locknut and the companion flange.

19. Remove the gear pack and shift rails and holding fixture from the extension housing. Place the assembly on a workbench.

20. If equipped, remove the spacer.
21. Remove the sling from around the shift rails, gear pack and the holding fixture.

22. Turn the shift rails approximately 45 degrees and lift the assembly off the mainshaft.

23. Using the shift rod support tool as a base, set the shift rail assembly on a workbench with the shift rails in a vertical position. Remove the gear selector interlock plate.

24. Mark the position of each gear shifter fork, shift rail, in the Shift Rod Support. Remove the shift fork and rail assemblies from the Shift Rod Support.

25. Lift the countershaft from the holding fixture. Lift the mainshaft from the holding fixture.