Disassembly

Special Tools:

1. Remove the clutch release hub and bearing and the clutch release lever.





2. Attach the transmission to the special tool.





3. Remove the lower case plug.





4. Remove the reversing lamp switch assembly.





5. Using the special tools, remove the extension housing fluid seal.

6. Note: Position the gearshift lever in NEUTRAL.





Remove the bolts and the gearshift lever.

7. CAUTION: Do not attempt to remove the gearshift offset lever with the extension housing bolted in place. A lug, located on the bottom of the gearshift offset lever, meshes with the detent plate preventing enough rearward movement of the gearshift offset lever to allow removal.





Drive the split pin downward as far as possible





8. Remove the 1 1. bolts and the identification tag.

9. 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 as an assembly.





10. Remove the gearshift offset lever, the split pin, the detent spring, and the detent ball.
11. Position the transmission with the output shaft facing upward.





12. Remove the full fill seal.





13. Remove the retaining ring, the OSS tone wheel, and the retaining ring.





14. Remove the retaining ring.





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





16. Remove the retaining ring.





17. Remove the selectable thrust washer.





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





19. Remove the bearing spacer.





20. Remove the retaining ring.





21. Remove the retaining ring.





22. Remove the thrust washer.





23. Remove the reverse gear.

24. Note: Mark the location of the blocking ring for assembly.





Remove the reverse speed blocking ring.





25. Remove the split pin from the fifth/reverse gear shifter fork.

26. CAUTION: Do not damage the hub splices.





Using a brass drift and a hammer, remove the reverse synchronizer hub.

27. CAUTION: Prevent the assembly from binding and cocking.





Simultaneously remove the fifth/reverse synchronizer sleeve, the fifth/reverse gear shifter fork, and the reverse synchronizer sleeve.





28. Remove the retaining ring.





29. Using the special tools, remove the fifth/reverse synchronizer hub.

30. Note: Mark the location of the blocking ring for assembly.





Remove the fifth speed blocking ring.





31. Remove the fifth gear.
32. Place the transmission on a bench.





33. 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 facing upward.





34. Remove the 12 bolts.

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





Separate the flywheel housing from the case.





36. Remove the input shaft.

37. Note: Mark the location of the blocking ring for assembly.





Remove the fourth speed blocking ring.





38. Remove the interlock bolt.





39. Remove the fifth/reverse gear shift rail.





40. Remove the fifth/reverse lever retaining clip.

41. CAUTION: The fifth/reverse lever pivot bolt threads have a thread lock coating on them. Significant break-away torque may be necessary to remove the bolt.





Remove the fifth/reverse lever pivot bolt.





42. Remove the fifth/reverse gear shift lever.

43. CAUTION: To prevent component damage, do not raise the output shaft assembly by lifting up on the third/fourth synchronizer assembly.





Push the output shaft assembly upward approximately 25 mm (1 inch) and remove the countershaft cluster gear.

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





Using two hands, lift the output shaft assembly out of the case.