Disassembly

Special Tools:

1. Position the transmission in the special tool.





2. Remove the lower case plug.





3. Remove the backup lamp switch.





4. Remove the gearshift lever.
^ Position the gearshift lever in NEUTRAL.
^ Remove the four bolts.
^ Remove the gearshift lever.





5. CAUTION: Do not attempt to remove the offset lever while the extension housing is bolted in place. A lug located on the bottom of the offset lever meshes with the detent plate. This prevents enough rearward movement of the offset lever to allow removal.

Drive the split pin down as far as possible.





6. Remove the 11 bolts and the identification tag.





7. CAUTION: The gearshift offset lever is under spring pressure.

While applying downward pressure on the gearshift offset lever, remove the extension housing and the gearshift offset lever.





8. Remove the gearshift offset lever, the roll pin, the shifter interlock spring and the detent ball.
9. Position the transmission with the output shaft facing up.





10. Remove the full fill seal.





11. Remove the OSS tone wheel.
^ Remove the snap ring
^ Remove the tone wheel.
^ Remove the snap ring.





12. Remove the output shaft retaining ring.





13. Using the special tools, remove the output shaft rear bearing.





14. Remove the output shaft bearing front retaining ring.





15. Remove the selectable thrust washer.





16. Remove the reverse driven gear and the needle bearing.





17. Remove the reverse driven gear bearing thrust washer.





18. Remove the retaining ring.





19. Remove the reverse drive gear retaining ring.





20. Remove the reverse drive gear spacer.





21. Remove the reverse drive gear.





22. Note: Mark the location of the blocker ring for assembly.

Remove the reverse drive gear blocker ring.





23. Remove the split pin from the fifth/reverse gearshift fork.





24. Remove the reverse synchronizer hub.





25. Note: Use caution to prevent the assembly from binding and cocking.

Simultaneously remove the reverse synchronizer sleeve from the output shaft and the fifth/reverse gearshift fork from the fifth/reverse shift rail, and the fifth/reverse synchronizer sleeve from the fifth/reverse synchronizer hub on the countershaft.





26. Remove the fifth/reverse synchronizer hub retaining ring.





27. Using the special tools, remove the fifth/reverse synchronizer.





28. Note: Mark the location of the blocker ring for assembly.

Remove the fifth gear blocker ring.





29. Remove the fifth gear.





30. Place the transmission on a bench. Remove the special tool from the front of the transmission and install it on the rear of the case. Position the transmission with the flywheel housing pointing up.





31. Remove the twelve bolts.





32. CAUTION: Pry only in the areas shown to prevent damage to the case.

Separate the flywheel housing from the case.





33. Remove the input shaft and the front bearing.





34. Note: Mark the location of the blocker ring for assembly.

Remove the fourth gear blocking ring.





35. Remove the shift interlock bolt.





36. Remove the fifth/reverse gearshift rail.





37. Remove the fifth/reverse shift level retaining clip.





38. CAUTION: The reverse shift lever anchor bolt was installed using threadlocker. Significant break-away torque may be required.

Remove the bolt.





39. Remove the fifth/reverse shift lever.





40. CAUTION: To prevent component damage, do not raise the mainshaft assembly by lifting up on the third/fourth synchronizer. Push upward on the mainshaft assembly approximately 25 mm (1 inch) to provide clearance.

Remove the countershaft cluster gear.





41. CAUTION: To prevent component damage, do not lift the mainshaft assembly by lifting up on the third/fourth synchronizer.

Using two hands, lift the mainshaft assembly out of the case.