Disassembly
Special Tool(s)
Disassembly
1. Remove the clutch release hub and bearing and the clutch release lever.
2. Attach the transmission to the special tool.
3. NOTE: Position a drain pan under the transmission.
Remove the case plug then rotate the transmission to a horizontal position.
4. Using the special tools, remove the extension housing fluid seal.
5. NOTE: Rotate the transmission to a vertical position.
NOTE: Position the gearshift lever in NEUTRAL.
Remove the bolts and the gearshift lever.
6. Inspect the gearshift offset lever insert and O-ring for wear or damage. Install a new insert as necessary.
7. NOTE: If necessary, remove the spring and plate for disassembly.
Remove the bolts and the shift spring and plate.
8. Using a 5/32 inch drift and a hammer, drive the split pin downward.
9. Remove the 12 bolts.
10. Using a flat-blade screwdriver, separate the extension housing, then remove the gearshift offset lever from the transmission case.
^ Remove the split pin from the gearshift offset lever during removal.
11. Remove the fifth/reverse gear lockout bolt.
12. Remove the fifth/reverse gear lockout.
13. Remove the shipping seal.
14. Remove the OSS sensor tone wheel retaining ring.
15. Using the special tools, remove the OSS sensor tone wheel.
16. Remove the OSS sensor tone wheel check ball.
17. Remove the fifth gear synchronizer retaining ring.
18. Using a 5/32 inch drift and a hammer, remove the pin from the fifth gear shift fork.
19. Remove the fifth gear shift fork, synchronizer assembly, synchronizer cone and the fifth gear as an assembly.
20. Remove the fifth gear clutch cone.
21. Remove the fifth gear synchronizer blocking ring.
^ Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.
22. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
23. Remove the synchronizer inserts and the springs.
24. Remove the needle bearings and the thrust washer.
^ The fifth gear needle bearing is three separate pieces: bearing spacer, bearing
^ Inspect the needle bearing for wear or damage. Install new bearings as necessary.
25. Remove the check ball.
26. Using a 5/32 inch drift and a hammer, drive out the split pin, then remove the third/fourth shift finger.
27. Using a 5/32 inch drift and a hammer, drive out the split pin, then remove the first/second shift finger.
28. Remove the main shift rail and the plastic spacer.
29. Remove the bolts and the shift interlock plate.
30. Using a magnet, remove the interlock pins.
^ One lock pin in the center rail, two between the rails.
31. Remove the three detent plugs, springs and the detents.
32. CAUTION: Do not remove all the bolts while in the horizontal position.
Remove the bolts.
^ Rotate the transmission to a horizontal position. Remove 12.bolts, leaving two opposing bolts in. Rotate the transmission to a vertical position, then remove the remaining two bolts.
33. Carefully pry the clutch housing from the transmission main case.
34. Remove the transmission main case from the clutch housing.
35. Lift the mainshaft 13 mm (0.50 in) upward, tilt the countershaft outward and remove the countershaft.
36. Remove the mainshaft and shift assembly.
37. Remove the input shaft.
38. Remove the shift rails and shift forks from the main shaft.
39. Remove the reverse idler shaft bolt. Remove and discard the seal.
40. Remove the reverse idler gear assembly.
41. Remove the reverse idler gear from the shaft.
^ Inspect the gear for wear or damage. Install a new gear as necessary.
42. Remove the reverse idler gear bearing.
^ The reverse idler gear is three separate pieces: bearing, spacer, bearing.
^ Inspect the bearing for wear or damage. Install new bearings as necessary.
43. Disassemble the clutch housing.
1 Remove the countershaft bearing cup and shim.
2 Remove the input shaft bearing cup and shim.
3 Remove the input shaft seal. Carefully pry out from the inside of the case.
44. Remove the rear countershaft bearing.
45. Remove the rear countershaft bearing cup and the rear output shaft bearing cup.