Overhaul (Disassembly)

Transmission Disassembly





Special Tool(s)

1. WARNING: Wear protective eyewear whenever using compressed air.

Clean the transmission exterior with solvent and dry with compressed air.

2. WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent and dry with compressed air.
3. Set the transmission on a work bench.





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





5. Using the special tool, remove the extension housing seal.





6. If equipped, remove the damper.





7. Remove the eight bolts and the extension housing.





8. Slide the first/second and third/fourth synchronizer sleeves forward to lock the transmission into first and third gears.
9. Remove the tone wheel snap ring, the lock bolt, then remove and discard the tone wheel.





10. Using the Transmission Shaft Locknut Socket, remove and discard the output shaft rear bearing lock nut.





11. Remove and discard the countershaft lock nut.





12. Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.





13. Remove the reverse idler shaft bolt.





14. Remove the reverse idler gear and bushing.





15. Using the special tools, remove the output shaft rear bearing.





16. Remove the output shaft reverse gear.





17. Remove the spacer.





18. Remove the countershaft reverse gear, the two countershaft reverse gear needle bearings, and the reverse synchronizer blocking ring.





19. Remove the thrust washer.





20. Remove the countershaft split washer.





21. Remove the fifth reverse gear shift rail bolt.





22. Remove the fifth reverse synchronizer, the gear shifter fork, and the reverse gear shift rail as an assembly.





23. Remove the countershaft fifth gear synchronizer blocking ring.





24. Remove the fifth reverse shift lever bolt and the nut, then remove the plate.





25. Remove the fifth and reverse shift lever.
^ Slide the fifth reverse shift lever and shaft assembly from the case.





26. Remove the countershaft fifth gear.





27. Remove the countershaft fifth gear split bearing and the race.
28. Remove the locking ball.





29. Remove the output shaft fifth gear.





30. Remove the rear bearing retainer.
1. Remove the retainer bolts.
2. Remove the bearing retainer.
31. Remove the clutch slave cylinder.





32. Remove the bolts.





33. Remove the main drive gear bearing retainer.
1. Install the Front Cover Remover into the clutch slave cylinder bolt locations.
^ Alternately tighten the bolts until the bearing retainer can be removed by hand.
2. Remove the main drive gear bearing retainer.





34. Remove the fluid baffle, the input bearing shim and the countershaft bearing shim.





35. Remove the front oil cooler tube bolt.





36. Remove the oil cooler tube.





37. Remove the input shaft front bearing race.





38. Remove the output shaft center bearing race.





39. Separate the input shaft from the output shaft.





40. Remove the output shaft.





41. Remove the input shaft and bearing.





42. Remove the countershaft cluster gear.





43. Inspect the countershaft for wear or damage.
Install a new countershaft as necessary.