Transmission Case and 6th Gear Disassembly
Transmission Case and 6th Gear DisassemblyComponent Identification: Case and 6th Gear
1. Place a wooden block under the 6th shift fork
- Wear eye protection
- Use a hammer and punch to drive out the Spring-Pin from the 6th shift fork
- Discard the Spring-Pin, it must be replaced with a new one
2. Remove the 6th Synchronizer Hub Selective Snap-Ring
- Wear eye protection
- Use 2-equal length flat blade screw-drivers
- Measure the Snap-Ring
- Record the measurement on the Selective Snap-Ring Sheet
- Place the Snap-Ring on the Selective Snap-Ring Sheet (see the Introduction)
3. Place a wooden block under the Inner Shift Rod to support the shaft
- Wear eye protection
- Use a punch and hammer to remove the Spring-Pin from the Inner shift rod support shaft
- Discard the spring-pin, it must be replaced with a new one
4. Remove the Inner Shift Lever
- It should come out easily
- If it does not, tap the Shift Rod with a soft faced hammer while prying upward on the inner shift lever
5. Rotate the Interlock Sleeve counterclockwise and remove it
Measure the 6th Gear Thrust Clearance:
- Use feeler gauges
- Write the clearance on the repair order
- Excess clearance would cause a concern in 6th gear
Measure the 6th Gear Radial Clearance:
- Use a dial indicator
- Write the measurement on the repair order
- A thrust clearance problem indicates a concern with the gear, bearing or shaft
- Record any parts that need replacement on the Repair Order
6. Get the 6th clutch hub puller SST 49 N017 2A1
- Assemble the 6th gear clutch hub puller to the 6th gear clutch hub
- Place a shop towel underneath the hub assembly to catch the steel balls and synchronizer key springs that may shoot out during this procedure
- Use a 1/2" breaker bar, a 1/2" ratchet and a 22mm socket to remove the 6th gear clutch hub and shift fork
- Place the 6th clutch hub in the plastic bag marked 6th
7. Remove 6th Shift Fork
8. Remove the 6th gear Synchronizer Ring
9. Remove 6th Gear
- Twist counterclockwise while pulling
- The split Needle Bearing {part #10} and Thrust Washer {part #11} may come off with 6th gear
10. Remove the 6th gear split Needle Bearing
11. Remove the 6th gear Thrust Washer
- Note the chamfered side faces the countershaft bearing
12. Remove the 6th Gear Thrust Washer Index Pin
13. Remove the Bearing Cover (four / T-45 Torx)
14. Remove the Mainshaft Rear Bearing Retainer Snap-Ring
- Discard the Snap-Ring. It must be replaced with a new one
Combine Step 15 and 16
15. Remove the plug from the bottom of the transmission (T-30 Torx)
16. Remove the Steel Ball and short Pressure Spring
- Place them in the bag marked springs and balls
17. Remove the Plug from the front of the transmission clutch housing (10mm Hex)
Combine Step 18 & 19
18. Remove the Shift Rod (a Steel Ball {19} will fall out the bottom of the transmission)
19. Remove the Steel Ball
- Place it in the bag marked Springs and Steel Detent Balls
20. Another Steel Detent Ball will come out of the transmission
- It should come out of the same hole as the last one; however, it may roll out another hole in the transmission case, so be careful and make sure you get the Steel Ball
- Place it in the bag marked Springs and Steel Detent Balls
Combine Step 21 and 22
21. Remove the Plug (T-30 Torx) from the passenger side of the transmission
22. Remove the long Pressure Spring and small Steel Detent Ball
- Place them in the bag marked Springs and Steel Detent Balls
23. Remove the Reverse Idler Shaft Bolts and Gaskets (two-12mm)
24. Remove the Bolt (17mm) from the passenger side of the transmission
Combine Step 25 and 26
25. Remove the Transmission Case
- Remove the case bolts (nine-12mm)
- You will have to break the sealant loose with pry-bars, on the tabs located on each side of the housing
26. A large Steel Detent Ball will fall out of the case when the case is separated
- Remove the short Pressure Spring from the case
- Place the Spring and Steel Detent Ball in the bag marked Springs and Steel Detent Balls
Optional
27. Remove the Spring Pin from the bearing cover
- Install SST49-N017-105 into the bearing cover and then install the SST into a vice with jaw protectors
- Use a hammer and punch to remove the spring pin
- If you remove the spring-pin, discard it, a new one must be used for assembly
Optional
28. Remove the pressure spring from the bearing cover
Optional
29. Remove the push pin from the bearing cover
Combine Step 30 thru 35
Use these steps to disassemble the 6th Gear Clutch Hub removed In Step #6 (Only necessary if the hub didn't come apart when it was removed)
30. Keep the Clutch Hub in its clear plastic bag (to catch all of the pieces)
- Remove the rear bearing Retainer Ring {30}
31. Remove the Sleeve from the hub while inside the bag
- Make sure you have:
- 3-balls {32}
- 3-keys {33}
- 3-springs {34}
- Clutch Hub {35}
- Keep all of the pieces together in the bag marked 6th
Inspect the 6th Gear Synchronizer Ring for wear:
- Use feeler gauges
- Write the measurement on the repair order
- If the ring is not at specification, replace the Synchronizer Ring
- Write down any parts that need replacement on the Repair Order