Disassembly and Assembly
TRANSMISSIONShift Cover:
1. Remove four bolts holding shift cover. Then lift off shift cover.
Roll Pin Removal:
2. Remove roll pin from rear offset lever.
Offset Lever Removal:
3. Slide offset lever from shaft.
Speed Sensor Removal:
4. Remove speed sensor located in the tail housing. Then remove the O-ring located in the housing bore.
Tail Housing Nut Removal:
5. Remove two tail housing nuts located at the top of the transmission tail housing.
Tail Housing Bolt Removal:
6. Remove the six tail housing to main case bolts.
Tail Housing Pry Points:
7. Gently pry tail housing off. Pry only at pry points and pull tail housing off case.
Tone Wheel Removal:
8. Remove speed sensor tone wheel and snap rings.
Bearing And Spacer Removal:
9. Remove main shaft roller bearing snap ring, roller bearing and spacers.
Reverse Gear Snap Ring And Thrust Washer:
10. Remove reverse gear snap ring and thrust washer.
Reverse Gear, Bearing And Synchronizer:
11. Remove reverse gear, bearing, wave washer and brass synchronizer ring.
Tap Reverse Synchronizer Forward:
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.
Shift Fork 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.
Synchronizer Snap Ring:
14. Remove synchronizer sleeve snap ring.
Shift Fork And Synchronizer Removal:
15. Remove shift fork and synchronizer sleeve from transmission as an assembly.
5-6 Gear Shift Fork Snap Ring:
16. Remove 5-6 gear shift fork snap ring.
Cluster Extension Shaft:
17. While holding 5-6 shift fork in place, pull cluster extension shaft straight out.
Shift Fork Removal:
18. Remove shift fork and 5-6 synchronizer sleeve.
6th Gear Removal:
19. Remove 6th gear, bearing and thrust washer.
Top Cover Plate:
20. Remove top cover plate bolts and pry off cover.
Skip Shift Roll Pin:
21. Remove roll pin from skip shift lever. Then slide skip shift lever off of shaft. Note the direction for reassembly.
Shift Detent Assembly:
22. Remove shift detent assembly. Check O-ring, replace if required.
Offset Roll Pin:
23. Drive roll pin down into front offset lever until it is loose.
Guide Plate Bolts:
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.
Offset Lever And Guide Plate:
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.
Torx Screw Location:
28. Remove two torx screws located on the top of the transmission case.
29. Remove clutch slave cylinder from transmission.
Adapter Bolt Location:
30. Remove 11 front adapter bolts. Leave one bolt in temporarily to hold the transmission front adapter in place.
Stand Transmission Upright:
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.
Transmission Case Removal:
32. Remove the one bolt left in the adapter. Then pry transmission case upward, away from front adapter and remove case.
Reverse Rail Assembly:
33. Remove reverse rail assembly.
Main Shaft And Shift Rail Removal:
34. Tilt cluster gear sideways. Then lift main shaft and shift rail assemblies out of the transmission.
Cluster Gear:
35. Remove cluster gear assembly.
Input Shaft Removal:
36. Lift input shaft from front adapter.
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 that pertains to that component.
MAIN SHAFT
During main shaft disassembly it is important not to interchange any of the snap rings.
Main Shaft O-Ring:
1. Remove main shaft O-ring. This O-ring is used to hold the main shaft tapered bearing in place during the manufacturing of this transmission.
Main Shaft Bearing:
2. Remove rear main shaft tapered bearing.
1st Gear And Bearing:
3. Remove 1st gear and bearing from shaft.
1-2 Snap Ring:
4. Remove 1-2 snap ring with snap ring pliers from main shaft.
Thrust Washer And Blocker Ring:
5. Remove 1-2 thrust washer and blocker ring assembly from main shaft.
Second Gear And Synchronizer Hub:
6. Using a press, remove second gear and synchronizer hub.
Synchronizer Snap Ring:
7. Remove 3-4 synchronizer snap ring.
Third Gear And 3-4 Synchronizer:
8. Using a press, remove third gear and 3-4 synchronizer hub and sleeve.
9. Clean, inspect and replace parts as required. To reassemble, reverse procedure.
CLUSTER EXTENSION
Bearing Spacer:
1. Remove bearing spacer.
CAUTION: Do not reuse original snap ring.
Snap Ring:
2. Remove snap ring and discard.
Gear And 5-6 Synchronizer Sleeve:
3. Remove gear and 5-6 synchronizer sleeve.
Needle Bearing:
4. Remove caged needle bearing.
5. Clean, inspect and replace parts as required. To reassemble, reverse procedure.
TAIL HOUSING
Idler Gear Bracket Bolts:
1. Remove the idler gear bracket bolts. Then remove the bracket.
Thrust Washer, Gear And Bearing:
2. Remove thrust washer, gear and bearing.
3. Remove gear shaft.
4. Clean, inspect and replace parts as required. To reassemble, reverse procedure.
ADJUSTMENTS
MAIN SHAFT BEARINGS
Input Shaft:
1. Install input shaft in to front adapter.
2. Install main shaft and bearing.
3. Install case and bolt together using all bolts.
5-6 Driven Gear:
4. Install 5-6 driven gear. All measurements will be taken from this gear.
5. Oscillate the input shaft and main shaft back and forth to seat bearings.
Dial Indicator:
6. Set up dial indicator as shown in.
7. Zero the dial indicator and then push up on the input shaft. Record the end play reading obtained. If there is no end play recorded, a thinner shim must be installed behind the bearing cone in the front adapter. Install 0.010 inch thinner shims until an end play reading can be read.
8. Once an end play reading is obtained, add 0.002 inch to the reading recorded in Step 7.
9. Add the number obtained in Step 8 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
10. Install a shim(s) behind the bearing cone in the front adapter equal to the number recorded in Step 9.
CLUSTER GEAR BEARINGS
Inspection Plug:
1. Remove inspection plug in the front adapter.
Cluster Gear:
2. Place cluster gear into front adapter.
3. Install case onto front adapter and tighten all adapter bolts.
4. Place cluster extension into back of transmission.
Special Tool:
5. Install special tool 6625 into front of transmission and hand tighten.
6. Stand transmission on end. The adapter should point upward.
Dial Indicator:
7. Set up dial indicator as shown in.
8. Zero the dial indicator and then push on the cluster gear shaft. Record the end play reading obtained. If there is no end play recorded, a thinner shim must be installed behind the bearing cone in the front adapter. Install 0.010 inch thinner shim until an end play reading can be read.
9. Once an end play reading is obtained, add 0.002 inch to the reading recorded in Step 8.
10. Add the number obtained in Step 9 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
11. Install a shim(s) behind the bearing cone in the front adapter equal to the number recorded in Step 10.
COUNTER SHAFT EXTENSION END PLAY
1. Assemble tail housing with original shim.
Special Tool:
2. Install special tool 6625. Snug down tool and then loosen two turns.
Dial Indicator:
3. Install dial indicator.
4. Zero the dial indicator and record the end play reading. If there is no end play recorded, a thinner shim must be installed. Install 0.010 inch thinner shim until an end play reading can be obtained.
5. Once an end play reading has been obtained. Then add the number obtained in Step 4 to the thickness of the shim that was in the transmission when the end play readings were taken. Record this number.
6. Install a shim(s) behind the bearing cone in the extension housing equal to the number recorded in Step 5.