Part 1

Transmission

Special Tool(s):

Disassembly (Steps 1-27)

NOTE: If any roll pins, retaining rings or bearings are removed during disassembly, install new components. Install bearings and bearing cups as a set.

1. WARNING: Make sure protective eyewear is in place.

Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
2. Attach the transmission to the special tool.





3. Remove the output flange nut, washer and oil seal.





4. Using the special tool, remove the output flange.





5. NOTE: Position a drain pan under the transmission.

Remove the case plug, then rotate the transmission to a horizontal position.





6. Using the special tool, remove the extension housing fluid seal.





7. Remove the output shaft speed (OSS) sensor.





8. Remove the 12 bolts.





9. Using a flat-blade screwdriver, separate the extension housing, then remove the gearshift offset lever from the transmission case.
^ Remove and discard the split pin from the gearshift offset lever during removal.





10. Remove the 5th/reverse gear lockout bolt.





11. Remove the snap ring.





12. NOTE: Always install a new bearing race if installing a new bearing.

Remove the output shaft bearing.
^ Inspect the bearing, install a new bearing if necessary.





13. Using the special tool, remove the output shaft bearing race.





14. Remove the bearing race spacer.
15. Remove the OSS sensor tone wheel retaining ring.





16. Using the special tools, remove the OSS sensor tone wheel.





17. Remove the OSS sensor tone wheel check ball.





18. Remove and discard the 5th gear synchronizer retaining ring.





19. Using a 5/32-inch drift and a hammer, remove and discard the pin from the 5th gear shift fork.





20. NOTE: A flat-blade screwdriver may aid in removal.

Using the special tool, remove the 5th gear shift fork, synchronizer assembly, synchronizer cone and the 5th gear as an assembly.





21. Remove the 5th gear clutch cone.





22. Remove the 5th gear synchronizer blocking ring.
^ Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.





23. Remove the 5th gear synchronizer sleeve from the synchronizer hub.





24. Remove the synchronizer inserts and the springs.





25. Remove the 5th gear needle bearings and the thrust washer.
^ Inspect the needle bearings for wear or damage. Install new bearings as necessary.





26. Remove the check ball.





27. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 5th/reverse lever fork. Discard the split pin.