Disassembly
DISASSEMBLY
Precaution
1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air, and check that there are no obstructions.
4. Wear eye protection when using compressed air to clean components.
Transmission
1. Remove the shift lever boot and gear shift lever, if necessary.
2. Remove the control case.
3. Remove the rear seal if necessary.
4. Remove the extension housing.
5. On 4x2 models, remove the anti-spill oil seal from the secondary shaft.
6. On 4x2 models, remove the speedometer drive gear and steel ball.
7. Disassemble in the order shown in the figure.
(1) Locknut
(2) Countershaft rear bearing
(3) Thrust washer
(4) Locknut (secondary shaft)
(5) Bolt
(6) Reverse idler gear Inspection
(7) Secondary shaft rear bearing
(8) Reverse gear
(9) Sleeve
(10) Countershaft reverse gear Inspection
(11) Needle bearings
(12) Synchronizer ring (reverse) Inspection
(13) Thrust washer
(14) Split washer
(15) 5th/reverse shift rod bolt
(16) Clutch hub and sleeve assembly (5th/reverse)
(17) 5th/reverse shift rod and fork
(18) Synchronizer ring (5th) Inspection
(19) Countershaft lever assembly
(20) 5th gear needle bearing
(21) 5th gear-secondary shaft
(22) 5th gear sleeve
(23) 5th gear ball
(24) Center bearing cover
(25) Front bearing cover
(26) Bolt
(27) Oil trough
(28) Primary shaft bearing outer race
(29) Countershaft front bearing
(30) Secondary shaft
(31) Primary shaft
(32) Countershaft gear Inspection
Rear seal
Remove the extension housing rear oil seal using seal remover T74P-77248-A, or equivalent.
Extension housing
1. Remove the extension housing bolts.
2. Pry gently at locations provided on the extension housing and transmission case.
3. On 4x2 models, remove the rear oil passage using a 1Omm socket.
Locknuts
1. Shift the transmission into 1st and 3rd gears.
2. Remove the countershaft locknut.
3. Remove the secondary shaft locknut using the SSTs.
Caution: Do not reuse the removed locknuts.
Reverse idler gear
1. Remove the reverse idler gear.
2. Remove the retaining ring, spacer, idler gear, needle bearings and thrust washer.
Secondary shaft rear bearing
Remove the secondary shaft rear bearing using the SST.
Caution: Be sure the tools are properly positioned so that the parts being removed are not damaged.
Front bearing cover
1. Remove the clutch release cylinder.
2. Remove the front bearing cover bolts.
3. Remove the front bearing cover by threading two M8 x 1.25 (4Omm or longer) bolts into the front bearing cover clutch release cylinder bolt locations.
Note: Bolts threaded into the clutch release cylinder bolt locations will bottom out and lilt the front bearing cover away from the transmission case. Do not remove the plastic scoop ring from the primary shaft at this time.
Primary shaft
1. Remove and discard the plastic scoop ring.
2. Remove the primary shaft bearing using Pinion Bearing Cone Remover T71 P-4621-B, or equivalent.
Caution:
Remove the bearing only if it needs to be replaced.
Secondary Shaft Parts
Disassemble in the order shown in the figure,
1. Roller bearing
2. Snap ring
3. Spacer
4. Needle bearing
5. Clutch hub and sleeve assembly (3rd/4th)
6. Synchronizer ring (3rd)
7. 3rd gear
8. Needle bearing
9. Center bearing-outer race
10. Center bearing-inner
11. 1st gear sleeve
12. 1st gear
13. 1st gear needle bearing
14. Synchronizer ring (1st)
15. Clutch hub and sleeve assembly (1st/2nd)
16. Synchronizer ring (2nd)
17. 2nd gear
18. 2nd gear needle bearing
Secondary shaft
1. Place the secondary shaft into a press.
2. Press out the 1st and 2nd gear components using the SST and Bearing Cone Replacer T53T-4621-B, or equivalent.
Note: SST Number: 49 UNO1 073 Bearing Cone Replacer Control Case
1 Remove the dust cover,
Dust cover
Remove the dust cover screws (Torx) and the dust cover.
2. Remove the back-up light switch and pin.
3. Remove the park/neutral position switch and pin.
4. Remove the shift rods,
Shift rod
Warning: Wear safety glasses while performing shift rod removal procedure.
1. Remove the shift fork interlock pins using a 5/32 in drift punch.
Note: Make sure all shift rods and gates are positioned in neutral.
2. Remove the shift gate interlock pins.
3. Remove the shift gates.
4. Remove the three shift rod service bore rubber plugs.
5. Cover the lock ball and friction device bores and seats with a clean cloth.
Caution: Failure to cover the cover lock ball and friction device bores could result in component loss.
6. Remove the 5th/reverse shift rod.
7. Remove the 1st/2nd shift rod.
8. Remove the 3rd/4th shift rod.
9. Remove the 5th/reverse cam lockout plate.
INSPECTION
Inspect all parts and repair or replace as necessary.
Gears
1. Inspect the synchronizer cones for wear.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.
Synchronizer Ring
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.
Note: Set the synchronizer ring squarely in the gear; then measure around the circumference.
3. Measure the clearance between the synchronizer ring and the flank surface of the gear.
Standard clearance: 1.5Omm {O.059 in}
Minimum: O.8mm {0.031 in}
Clutch Hub Assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer keys for damage, wear, and cracks.
4 Measure the clearance between the hub sleeve and shift fork.
Clearance
Reverse Idler Gear
1. Inspect the gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the retaining ring.
Standard clearance: O.1O-0.2Omm {O.OO39-O.OO78 in}
Bearing
Note: When replacing the bearing, replace the bearing and race as a set. Inspect for damage and rough rotation.
Countershaft Gear
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Measure the countershaft gear runout.
Countershaft gear runout: O.O5Omm {O.0020 in} max.
Speedometer Gears
1. Inspect the teeth for damage and wear.
2. Inspect the 0-ring for damage and wear.