A. Transmission Disassemble

^ Tools Required
- J 22912-01 Bearing And Gear Puller
- J 8433 Heavy Duty Pulley Puller
- J 3289-20 Bench Fixture
- J 36842 Holding Fixture





1. Clean the exterior of the transmission assembly with appropriate solvent.
2. Install the J 36842 on the transmission.
3. Mount the transmission on a workbench. Use the J 3289-20.
4. Remove the transmission oil drain plug.
5. Drain the transmission fluid into a suitable container.

IMPORTANT: Position the offset lever in neutral (centered). This will avoid driving the roll pin into the detent plate making further disassembly extremely difficult. Do not remove the offset lever while the extension housing is still bolted in place. The lever has a positioning lug engaged in the housing detent plate. The lug prevents moving the lever far enough for removal.





6. Drive out the roll pin from the offset lever.
7. Remove the extension housing-to-transmission case bolts.





8. Remove the housing and the offset lever as an assembly.





9. Remove the detent ball and spring from the offset lever.





10. Remove the roll pin from the extension housing or from the offset lever.
11. Remove the oiling funnel from the rear of the countershaft.
12. Remove the bolts attaching the transmission case cover and the shift fork assembly to the case. Note the location of these bolts for assembly reference. Two of the cover bolts are alignment-type dowel bolts.





13. Remove the case cover.





14. Remove the following parts:
14.1. The reverse lever spring clip
14.2. The pivot bolt





15. Remove the backup lamp switch.





16. Remove the 5th speed gear synchronizer retainer ring and the retainer from the rear of the countershaft.





17. Unhook the reverse lock spring from the side of the transmission case.





18. Remove the following parts as an assembly:
18.1. The 5th speed gear
18.2. The synchronizer
18.3. The shift fork
18.4. The shift rail (If necessary, rotate the shift rail in order to disengage the shift rail from the reverse lever assembly.)





19. Remove the retainer ring from the mainshaft.





20. Remove the speedometer reluctor and the reluctor retainer ball.





21. Remove the retainer ring from the 5TH speed driven gear.





22. Remove the following parts:
22.1. The front bearing retainer bolts
22.2. The front bearing retainer
22.3. The front bearing race
22.4. The end play shims





23. Remove the main drive gear from the transmission case. Rotate the main drive gear until the flat surface faces the countershaft. Do not to drop the 15 roller bearings, the thrust bearing, or the bearing race from the main drive gear.





24. Remove the 4th speed gear blocker ring from the 3rd/4th speed gear synchronizer.
25. Remove the mainshaft rear bearing race. If the bearing race sticks, the bearing race is probably misaligned in the case bore. Move the mainshaft back and fourth in order to loosen the bearing race.





26. Remove the mainshaft from the transmission case.





27. Remove the reverse gear fork assembly from the transmission case.





28. Bend the locking tabs away from the countershaft retainer bolts.
29. Remove the following parts:
29.1. The countershaft retainer bolts
29.2. The countershaft retainer
29.3. The shims





30. Drive the roll pin out of the forward end of the reverse idler shaft.
31. Remove the following parts:
31.1. The reverse idler gear shaft
31.2. The rubber O-ring seal
31.3. The reverse idler gear





32. Remove the rear countershaft bearing race.





33. Remove the countershaft bearing. Use the J 8433 and the J 22912-01.





34. Remove the countershaft from the transmission case.