Disassembly

Special Tools:

Special Tools:

1. Position the transmission in the special tool.





2. Remove the case plug.





3. Remove the gearshift lever.
^ Position the gearshift lever in NEUTRAL.
^ Remove the four bolts.
^ Remove the turret cover.





4. CAUTION: Do not attempt to remove the gearshift offset lever while the extension housing is 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.

Remove the gearshift offset lever roll pin and the gearshift bushing.





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





6. Remove the seven bolts.





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, roll pin, shifter interlock spring and detent ball.





9. Remove the bolts.





10. Remove the case cover.
^ Lift the case cover and slide toward the filler plug side of the case to clear the reverse gearshift lever.
^ Remove the case cover.





11. Remove the fifth gear shifter fork roll pin.
^ Support the reverse gear shift rail with a block of wood.
^ Remove the fifth gear shifter fork roll pin.

12. Remove the snap ring, retainer, brake ring and synchronizer blocking ring (7107).





13. Remove the fifth speed cluster gear, synchronizer and the fifth gear shifter fork.





14. Remove the reverse gearshift lever retaining ring.





15. Note: Do not remove the reverse gearshift lever at this time.

Using a TORX(R) bit driver, remove the shift rail rear pin.





16. Remove the backup lamp switch.





17. Remove the reverse gearshift lever.
1Rotate the reverse gear shift rail clockwise to disengage the ball stud from the reverse gearshift lever.
2 Pull the reverse gear shift rail rearward slightly and rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail.





18. Remove the VSS tone wheel.
^ Remove the retaining ring.
^ Remove the tone wheel.
^ Remove the retaining clip.

19. Remove the four bolts and the main drive gear bearing retainer.





20. Remove the input shaft.
^ Rotate the input shaft until the flat on the fourth gear clutching teeth align with the countershaft cluster gear.
^ Remove the input shaft. Be careful not to drop the 15 roller bearings and spacer from the rear of the input shaft.





21. Remove the fourth gear synchronizer blocking ring.





22. Note: If the output shaft rear bearing cup sticks, it is misaligned in the case bore. To free the output shaft rear bearing cup, work the output shaft back and forth in the case.

Remove the output shaft rear bearing cup.





23. Remove the output shaft assembly.





24. Note: Observe the location of the reverse gearshift lever, shift fork, and the reverse positioning spring.

Note: Observe the rotation action of the reverse positioning spring.

Holding the reverse gearshift lever, lift as straight up as possible to remove the reverse gearshift lever, reverse shift fork, and the reverse positioning spring as an assembly.





25. Remove the roll pin.





26. Remove the reverse idler gear and bushing.
^ Remove the reverse idler shaft.
^ Remove the reverse idler gear and bushing and the reverse gear overtravel stop.





27. Using the special tool, flatten the tabs on the countershaft bearing retainer.





28. Remove the four bolts and the countershaft rear bearing retainer and shim.





29. Note: If the rear countershaft bearing race sticks in the case, it is misaligned in the case bore. To free the race, work the countershaft cluster gear back and forth.

Remove the rear countershaft bearing race.





30. Using the special tools, remove the rear countershaft bearing.





31. Move the countershaft cluster gear rearward through the bearing bore. Tilt the assembly upward and remove it from the case.