1. Transmission Disassemble

Transmission Disassemble

^ Tools Required
- J 23907 Slide Hammer With Bearing Adaptor
- J 36509 Detent Spring Plug Remover
- J 41663 Transmission Assembly Pallet with Main Shaft Adapter





1. Remove the backup lamp switch from the rear case.
2. Remove the vehicle speed sensor from the rear case.





3. Remove the shift shaft detent pin from the clutch housing.





4. Using the J 36509 in the detent plug and the J 23907 remove the following components from the clutch housing:
^ The shift shaft detent plug
^ The shift shaft spring
^ The shift shaft plunger
5. Remove the 5 bolts retaining the input shaft-bearing retainer to the clutch housing.





6. Use a suitable prying tool to remove the input shaft bearing retainer.
7. Remove the input shaft retaining ring.





8. Remove the input shaft seal from the input shaft bearing retainer.





9. Remove the 9 bolts securing the clutch housing to the rear case.

Notice: The case sealing surface is a machine surface. Prevent the case sealing surface from getting nicks, scratches or other damage. Damage to the case sealing surface may cause leakage.

10. Using a soft-face hammer, tap on the clutch housing in order to separate the clutch housing from the rear case.
11. Remove the countershaft roller bearing from the countershaft.





12. Remove the shift shaft roll pin from the shift shaft lever.
^ Rotate the shift shaft lever and the shift rail bushing.
^ Support the shift shaft end while driving out the shift shaft lever roll pin.
^ Allow the roll pin to clear the 2nd gear during removal.





13. Remove the shift shaft socket roll pin.
^ Do not bend the shift rail when removing the roll pin.
^ Use a 5 mm (3/16 inch) drift punch in order to remove the roll pin.
^ The roll pin will fall into the rear housing.





14. Remove the following components:
^ The shift shaft
^ The shift shaft socket
^ The shift shaft lever
^ The shift rail bushing





15. Rotate the 3rd/4th gear shift fork counterclockwise.
16. Remove the 3rd/4th shift fork.
The 5th/reverse gear shift fork and the 1st/2nd gear shift fork are removed after removing the rear case.





17. Install the rear case gear assembly on the J 41663.
18. Remove the 2 bolts attaching the reverse idler gear shaft retainer and the reverse idler shaft support collar to the rear case.





19. Remove the bolts securing the main shaft bearing retainer to the center of the rear case.
20. Remove the rear case from the gear assemblies.





21. Remove the mainshaft bearing retainer.
22. Remove the reverse idler gear assembly.





23. Remove the 5th/reverse gear shift fork.
24. Remove the 1st/2nd gear shift fork.
25. Remove the countershaft from the J 41663.
26. Remove the mainshaft assembly from the J 41663.





27. Remove the mainshaft front bearing from the input shaft.