Part 1
TransmissionSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Disassembly (Steps 1-25)
NOTE: During disassembly, if any roll pins, retaining rings or bearings are removed, install new components. Install bearings and bearing cups as a set only.
1. WARNING: Make sure protective eye wear is in place.
Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
2. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.
3. Remove the clutch hydraulic line clip and the clutch hydraulic line connector.
4. Attach the transmission to the special tool.
5. Rotate the transmission to a horizontal position.
6. NOTE: Position a drain pan under the transmission.
If the transmission was not drained during removal, drain the transmission.
7. Rotate the transmission to a vertical position.
8. Remove the output shaft flange nut.
9. Using the special tools, remove the output shaft flange.
10. Remove the 4 shift detent cover bolts and the shift detent cover.
11. Remove the 8 bolts and carefully separate the extension housing from the transmission.
12. Using the special tool, remove the bearing race and the spacer.
13. Remove the output shaft speed (OSS) sensor tone wheel snap ring.
14. Remove the tone wheel and the ball.
15. Remove the snap ring, the upper spacer, the rear output shaft roller bearing and the lower spacer.
^ Inspect the rear output shaft roller bearing for wear or damage. Install a new bearing as necessary.
16. NOTE: Position the gearshift lever in 3rd/4th neutral position.
Using a 5/32-inch drift and a hammer, drive the roll pins downward, then remove the reverse shift rail.
^ Discard the roll pins.
17. Remove these components:
1. The reverse gear snap ring.
2. The reverse gear thrust washer.
3. The reverse gear.
^ Discard the reverse gear snap ring.
^ Inspect reverse gear for wear or damage.
Install a new gear as necessary.
18. Remove the reverse gear needle bearing.
^ Inspect the needle bearing for wear or damage. Install a new bearing as necessary.
19. Remove the 3 piece reverse gear synchronizer blocking ring.
20. Remove the reverse gear synchronizer snap ring.
21. Remove the reverse shift fork snap ring.
22. Remove the reverse shift fork and the reverse synchronizer.
^ The synchronizer hub is a tight fit on the shaft, and may need to be removed separately. After removing the fork and synchronizer sleeve, carefully pry off the synchronizer hub.
23. Inspect the synchronizer for:
^ Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
^ Check keys for wear or distortion. Check the springs for distortion. Install a new synchronizer as necessary.
24. Inspect the synchronizer blocking ring for:
^ Check for wear or damage. Install a new synchronizer blocking ring as necessary.
^ Check the clearance between the synchronizer blocking ring and the gear.
- Position the blocking ring onto the gear. Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear.
- Insert a feeler gauge and measure the clearance, while applying pressure and rotating the blocking ring. The measurement should be the same around the entire circumference. If the clearance is less than 0.75 mm (0.030 inch), install new blocking ring.
25. Remove the 5th driven gear split ring and retainer.
