Transmission Assembly

Disassemble (Figures 1 through 15)

Tool Required:
J 3289-20 Base Holding Fixture
J 8763-02 Holding Fixture C-Clamp
J 8763-21 Balance Bracket for C-Clamp
J 36824 Transmission Adapters
J 36509 Detent Sprint Plug Remover
J 23907 Slide Hammer
J 36825 4WD Output Shaft Oil Seal Remover (4WD models only)
J 36515 Assembly Pallet
J 36515-15 Mainshaft Adapter
J 36515-16 Countershaft Adapter
J 24420-B Gear Puller (2WD models only)
J 21427-01 Speedometer Gear Puller Adapter (2WD models only)
J 26941 Output Shaft Oil Seal Remover (2WD only)





1. Idler shaft support bolt (311) and bottom two bolts (312) (figure 5).





^ J 8763-21 onto J 8763-02 (figure 6).
^ J 36824 onto the transmission case.
^ J 8763-02 onto J 36824.





2. Backup lamp switch assembly (313) (figure 7).
3. Shift shaft block-out bushing pin (236).
4. Bolt (317) and electronic speed sensor assembly (314) (2WD models only).

5. Detent plug (245) using J 36509 and J 23907, spring (244), and plunger (243) (figure 7).





6. Output shaft oil seal (320) using J 36825 and J 23907 (figure 8) (4WD models only).

^ Use J 36825 by screwing into one of the three perforated holes in the seal (4WD models only).

7. Position transmission vertically.





8. Six bolts (204) and input shaft bearing retainer assembly (205) (figure 9).
A. Tap clutch release bearing pilot with a rubber mallet.
B. Save the input bearing retainer washer.
9. Snap ring (210) and shim (212).
10. Position transmission horizontally.





11. Front housing to rear housing bolts (312) (figure 10).
12. Drive dowels (321) into front housing.
13. Front housing (200).
14. Countershaft bearing (35).
15. Idler shaft support (310).
^ Snap out.
16. Move all shift forks forward to engage fourth, second, and reverse gears.
17. Roll pin (105) (figure 1).

Important
A. Support the shift shaft (108) end while driving out lever roll pin.
B. Allow roll pin to clear second gear.
C. Do not loose shift lever detent ball (106) and spring (107).
18. Place all gears in neutral. Then engage fifth gear.
19. Push shift shaft (108) all the way into the housing (300) or (301).
20. Shift shaft socket assembly roll pin (113) (figure 1). Rotate input shaft until gap in the fifth/reverse synchronizer hub is directly under the roll pin.

^ Drive shift socket pin down using a 5 mm (3/16-inch) punch.
^ Pin will fall into the case.

NOTICE:
Excessive force will "peen" the shift shaft and damage the rear housing shift shaft bearing (309) causing increased shift effort.

21. Shift shaft (108), shift shaft socket assembly (114), anti-rotation bracket (112), biasing spring (109), lever (104), and shift shaft block out bushing (103).
22. Rotate third-fourth shift fork (102) counterclockwise and remove.
23. Loosen, but do not remove, 3 bolts (304) on the rear of case (2WD only).





24. Install J 36515-15 and J 36515-16 onto the input and countershaft. Install J 36515 to the transmission assembly (figure 11).
25. J 8763-02 and J 36824 from the housing.

26. Bolts (304) from the rear housing (2WD only) (figure 12).

27. Output shaft bearing snap ring (43) (4WD only).








28. Tap housing with a rubber mallet and remove rear housing from assembly (figures 12 and 13).
29. Output shaft bearing retainer (302) (2WD models only) (figure 12).





30. Shift forks (100 and 101) (figure 14).
31. Reverse idler gear (46).
32. Countershaft (53).





33. Bearing (203) (2WD models only).
^ Slide the snap ring (43) away from the rotor to make clearance for J 21427-01 (figure 15).
34. Speed sensor rotor (45) using J 21427-01 and J 24420-B (2WD models only).
- Do NOT reuse rotor after removal.
35. Snap ring (43) (2WD models only).
36. Snap ring (44) (2WD models only).
37. Bearing assembly, output shaft (33) (2WD models only).
38. Mainshaft assembly (4) or (5) (figure 14).

Important
Leave the synchronizer ring (2) on the third-fourth synchronizer assembly (7) to prevent the synchronizer detent balls (9) from popping out.

39. Input shaft gear (1) and pilot bearing (3).