Transmission
DISASSEMBLY
1. Remove four bolts holding shift cover. Then lift off shift cover.
2. Remove roll pin from rear offset lever.
3. Slide offset lever from shaft.
4. Remove speed sensor located in the tail housing. Then remove the O-ring located in the housing bore.
5. Remove two tail housing nuts located at the top of the transmission tail housing.
6. Remove the six tail housing to main case bolts.
7. Gently pry tail housing off. Pry only at pry points and cull tail housing
8. Remove speed sensor tone wheel and snap rings.
9. Remove main shaft roller bearing snap ring, roller bearing and spacers.
10. Remove reverse gear snap ring and thrust washer.
11. Remove reverse gear, bearing, wave washer and brass synchronizer ring.
12. Under normal use the reverse synchronizer is forced against the snap ring. This makes snap ring removal difficult. Lightly tap the reverse synchronizer forward to relieve pressure on snap ring. This will make it easier to remove the snap ring.
13. Remove reverse shift fork snap ring. Use a new snap ring when assembling. The flat side of the snap ring must face rearward.
14. Remove synchronizer sleeve snap ring.
15. Remove shift fork and synchronizer sleeve from transmission as an assembly.
16. Remove 5-6 gear shift fork snap ring.
17. While holding 5-6 shift fork in place, pull cluster extension shaft straight out.
18. Remove shift fork and 5-6 synchronizer sleeve
19. Remove 6th gear, bearing and thrust washer.
20. Remove top cover plate bolts and pry off cover.
21. Remove roll pin from skip shift lever. Then slide skip shift lever off of shaft. Note the direction.
22. Remove shift detent assembly. Check O-ring, replace if required.
23. Drive roll pin down into front offset lever until it is loose.
24. Remove two torx bolts from guide plate.
CAUTION: There is a ball and spring located between the guide plate and offset lever. It may pop out when disassembling.
25. Slide offset lever and guide plate out the rear of the transmission.
26. Separate offset lever and guide plate to remove the roll pin that was driven down in Step 23 of this procedure.
27. Remove 5-6 driven gear using special tool 6444 puller and 6622 jaws, or equivalents.
28. Remove two torx screws located on the top of the transmission case.
29. Remove clutch slave cylinder from transmission.
30. Remove 11 front adapter bolts. Leave one bolt in temporarily to hold the transmission front adapter in place.
31. Stand the transmission on front adapter. You will have to place the transmission between two benches or have a hole in your bench to allow the input shaft to hang freely.
32. Remove the one bolt left in the adapter. Then pry transmission case upward, away from front adapter and remove case.
33. Remove reverse rail assembly.
34. Tilt cluster gear sideways. Then lift main shaft and shift rail assemblies out of the transmission.
35. Remove cluster gear assembly.
36. Lift input shaft from front adapter.
NOTE: At this point the transmission has been disassembled into subassemblies:
^ Main Shaft
^ Cluster Extension
^ Tail Housing
^ Cluster Gear
^ Input Shaft
^ Transmission Housing
To service a particular subassembly, refer to the Disassembly And Assembly section that pertains to that component.
ASSEMBLY
Clean, inspect and replace parts as required. To reassemble, reverse procedure.