Disassembly

DISASSEMBLY

1. Remove four shift cover bolts and remove shift cover (Fig. 4).

2. Remove roll pin from rear offset lever (Fig. 5).

3. Slide offset lever from shaft (Fig. 6).

4. Remove speed sensor located in the tail housing (Fig. 7). Then remove the O-ring located in the housing bore.

5. Remove the two tail housing nuts located at the top of the transmission tail housing (Fig. 8).

6. Remove the six tail housing bolts (Fig. 9).

7. Gently pry tail housing off (Fig. 10) and pull tail housing off case.

CAUTION: Pry only at pry points.

8. Remove speed sensor tone wheel and snap rings (Fig. 11).

9. Remove main shaft roller bearing snap ring, roller bearing and spacers (Fig. 12).

10. Remove reverse gear snap ring and thrust washer (Fig. 13).

11. Remove reverse gear, bearing, wave washer and brass synchronizer ring (Fig. 14).

12. Under normal use the reverse synchronizer is forced against the snap ring. Lightly tap the reverse synchronizer forward (Fig. 15) to relieve pressure on the snap ring and remove the snap ring..

13. Remove,reverse shift fork snap ring (Fig. 16). A new snap ring must be used for assembling.

14. Remove synchronizer sleeve snap ring (Fig. 17).

15. Remove shift fork and synchronizer sleeve from transmission as an assembly (Fig. 18).

16. Remove 5-6 gear shift fork snap ring (Fig. 19).

17. While holding 5-6 shift fork in place, pull cluster extension shaft straight out (Fig. 20).

18. Remove shift fork and 5-6 synchronizer sleeve (Fig. 21).

19. Remove sixth gear, bearing and thrust washer (Fig. 22).

20. Remove top cover plate bolts and pry off cover (Fig. 23).

21. Remove roll pin from skip shift lever (Fig. 24). Then slide skip shift lever off of shaft. Note the direction for assembly.

22. Remove shift detent assembly (Fig. 25). Check O-ring, replace if required.

23. Drive roll pin down into front offset lever until it is loose (Fig. 26).

24. Remove two torx bolts from guide plate (Fig. 27).

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 (Fig. 28).
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 Puller 6444 and Jaws 6622.

28. Remove two torx screws located on the top of the transmission case (Fig. 29).
29. Remove clutch slave cylinder from transmission.

30. Remove 11 front adapter bolts (Fig. 30). Leave one bolt in temporarily to hold the transmission front adapter in place.

31. Stand the transmission on front adapter (Fig. 31). 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 (Fig. 32).

33. Remove reverse rail assembly (Fig. 33).

34. Tilt cluster gear sideways. Then lift main shaft and shift rail assemblies out of the transmission (Fig. 34).

35. Remove cluster gear assembly (Fig. 35).

36. Lift input shaft. from front adapter (Fig. 36).

MAIN SHAFT

CAUTION: Main shaft snap rings are not interchangeable.

1. Remove main shaft O-ring (Fig. 37). This O-ring is used to hold the main shaft tapered bearing in place during the manufacturing of this transmission.