Disassembly
Precaution1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and check that there are no obstructions.
Housing Components
NOTE: The front and rear oil seals do not need to be removed unless you are replacing them.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Note
Extension Housing
Turn the extension housing to remove it.
Transmission Case
Remove the transmission case from the intermediate housing and gear assembly by using the SST.
On-vehicle Replacement
Oil seal (rear)
1. Raise the vehicle and support it with safety stands.
2. Remove the propeller shaft.
3. Remove the oil seal from the extension housing.
4. Apply the specified oil to a new oil seal.
5. Install the new oil seal by using the SST.
6. Install the propeller shaft.
7. Inspect the oil level.
Shift Fork and Shift Rod Parts
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Note
Clip
Remove the clip, spacer, and spring from the 5th/Reverse shift rod.
Mainshaft and Countershaft Parts
1. Snap ring
2. Washer
3. Retaining ring
4. C-washer
5. Mainshaft rear bearing
6. Retaining ring
7. C-washer
8. Thrust lock washer
9. Steel ball
10. Locknut (Countershaft)
11. Countershaft rear bearing
12. Counter 5th gear
13. Spacer
14. 5th gear
15. 5th synchronizer ring
16. Locknut (Mainshaft)
17. Clutch hub assembly (5th/Reverse)
18. Reverse synchronizer ring
19. Reverse gear
20. Bearing
21. Bearing race
22. Washer
23. Counter reverse gear
24. Main drive gear bearing
25. Snap ring
26. Countershaft front bearing
27. Bearing housing assembly
28. Mainshaft gear assembly
29. Main drive gear
30. 4th synchronizer ring
31. Bearing
32. Washer
33. Countershaft
34. Spacer
35. Synchronizer key springs
36. Clutch hub sleeve
37. Synchronizer key
38. Clutch hub
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Note
Mainshaft rear bearing
Remove the mainshaft rear bearing by using the SSTs.
Locknut (Countershaft)
1. Shift the clutch hub sleeves into 1st and reverse gears to lock the rotation of the mainshaft.
2. Use a suitable tool to uncrimp the tabs of the locknut.
3. Connect the SST to the mainshaft and secure it in a vise.
4. Remove the locknut.
Countershaft Rear Bearing
Remove the countershaft rear bearing by using the SST.
Locknut (Mainshaft)
1. Shift the clutch hub sleeves into 1st and reverse gears to lock the rotation of the mainshaft.
2. Use a suitable tool to uncrimp the tabs of the locknut.
3. Secure the bearing housing in a vise.
4. Remove the locknut by using the SST.
Main Drive Gear Bearing
Remove the main drive gear bearing with a suitable pipe.
Outer diameter of pipe: 70.0 mm (2.76 in)
Countershaft Front Bearing
Remove the countershaft front bearing by using the SST.
Bearing Housing Assembly
Remove the bearing housing by lightly tapping the countershaft with a copper hammer.
Mainshaft Parts
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Note
3rd/4th Clutch Hub Assembly
1. Position the SST between 2nd and 3rd gears, and hold the mainshaft from underneath.
2. Press the mainshaft out of the clutch hub assembly (3rd/4th) and 3rd gear.
1st/2nd Clutch Hub Assembly
Hold the mainshaft, and press the 1st/2nd clutch hub assembly, 2nd synchronizer assembly, and 2nd gear from the mainshaft.
Bearing Housing Assembly
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Not
Reverse Idler Gear Shaft
1. Remove the reverse idler gear shaft installation bolt
2. Support the reverse idler gear shaft, and press it from the bearing housing.
Mainshaft Front Bearing
Support the mainshaft front bearing, and press it out from the bearing housing by using a suitable pipe.
Outer diameter of pipe: 70.0 mm (2.76 in)
Countershaft Center Bearing
NOTE: If countershaft center bearing is replaced, replace the spacer also.
Support the countershaft center bearing, and press it out from the bearing housing by using a suitable pipe.
Outer diameter of pipe: 50.0 mm (1.97 in)
Extension Housing Parts
Disassemble in the order shown in the image.