Part 2
TransmissionDisassembly (Steps 26-51)
26. Using the special tools, remove the 5th driven gear.
27. Remove the 5th/6th shift fork snap ring.
^ Discard the snap ring.
28. Remove the reverse drive gear snap ring.
^ Discard the snap ring.
29. Using a suitable puller, remove the reverse drive gear.
^ Inspect reverse drive gear for wear or damage. Install a new gear as necessary.
30. Remove these components:
1. The 5th drive gear snap ring.
2. The 5th drive gear thrust washer.
3. The 5th drive gear.
^ Discard the snap ring.
^ Inspect the 5th drive gear for wear or damage. Install a new gear as necessary.
31. Remove the 5th/6th drive gear needle bearing and spacer.
32. Remove the 5th/6th gear synchronizer intermediate cone, the 5th/6th gear synchronizer outer cone and the 5th/6th gear synchronizer blocking ring.
33. Remove the snap ring.
34. Remove the 5th/6th gear shift fork and 5th/6th gear synchronizer.
^ The synchronizer hub is a tight fit on the shaft, and may need to be removed separately. Using a suitable puller, remove the synchronizer hub.
35. Remove the 5th/6th gear synchronizer intermediate cone, the 5th/6th gear synchronizer outer cone and the 5th/6th gear synchronizer blocking ring.
36. Remove 6th gear.
37. Remove the 6th gear needle bearing.
38. Remove 9 of the clutch housing-to-transmission case bolts.
39. Remove the vent hose.
40. NOTE: Rotate the transmission to a vertical position.
Remove the shift lever guide bolts.
41. Remove the 5th/6th and reverse shift lever detent bolt, spring and detent.
42. Remove the 2 remaining clutch housing-to-transmission case bolts, then remove the transmission case and the front offset lever.
^ Slide the transmission case upward, off the output shaft and shift rails. Hold the offset lever against the guide plate.
43. Remove the 6th gear spacer and thrust washer.
44. Rotate the 5th/6th and reverse shift levers from the shift interlock plate, then remove the 5th/6th and reverse shift rail assembly.
45. Lift up the output shaft, then remove the countershaft.
46. Remove the output shaft and shift rail as an assembly. Separate the shift rail assembly from the output shaft on the work bench.
47. Remove the input shaft, the 4th gear synchronizer blocking ring and the double cone (3 rings).
48. Remove the countershaft bearing cup and the countershaft shim.
^ Inspect the cup for wear or damage. Install a new cup and bearing as necessary.
^ Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter plate as necessary.
49. Remove the input shaft bearing cup and input shaft shim.
^ Inspect the cup for wear or damage. Install a new cup and bearing as necessary.
^ Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter plate as necessary.
50. Remove and discard the input shaft seal.
51. WARNING: Make sure protective eye wear is in place.
Clean the transmission clutch housing with solvent and dry with compressed air. Inspect the clutch housing for cracks. Clean and check the sealing surface for nicks or scratches.
^ If the clutch housing is cracked, install a new housing. If the sealing surface has nicks or scratches, use a soft stone or crocus cloth to remove.