Part 2

Transmission

Disassembly (Steps 28-55)
28. Remove the main shift rail and the 2 plastic spacers.





29. Remove and discard the 2 plastic spacers.





30. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 3rd/4th shift finger. Discard the split pin.





31. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 1st/2nd shift finger. Discard the split pin.





32. Remove the bolts and the shift interlock plate.





33. Using a magnet, remove the interlock pins.
^ One lock pin in the center rail, 2 between the rails.





34. Remove the 5th/reverse gear lockout side bolt.





35. Remove the 5th/reverse gear lockout top bolt, then remove the seal, arm and spring.





36. CAUTION: Do not remove all the bolts while in the horizontal position.

Remove the bolts.
^ Rotate the transmission to a horizontal position. Remove 12 bolts, leaving 2 opposing bolts in. Rotate the transmission to a vertical position, then remove the remaining 2 bolts.





37. Carefully pry the clutch housing from the transmission main case.





38. Remove the transmission main case from the clutch housing.
^ The countershaft bearing will remain in the housing. Lightly tap the bearing to remove.
^ Inspect the bearing and install a new one if necessary.





39. Remove the 3 detent plugs.





40. Remove the 3 detent springs.
41. Remove the 3 detents.





42. Using a jack and a block of wood, lift the mainshaft 13 mm (0.50 inch) upward, then tilt the countershaft outward and remove the countershaft.





43. While holding the mainshaft, release the jack and remove the mainshaft and shift assembly.





44. Remove the input shaft.





45. Carefully remove the shift rails and shift forks from the main shaft.





46. Remove the reverse idler shaft bolt. Remove and discard the seal.





47. Remove the reverse idler gear assembly.
48. Remove the reverse idler gear from the shaft.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





49. Remove the reverse idler gear bearing.
^ Inspect the bearing for wear or damage.
Install new bearings as necessary.





50. Release the clip and remove the clutch slave cylinder connector.
51. Remove the clutch slave cylinder.





52. Remove and discard the plastic retainer.





53. Disassemble the clutch housing.
1. Remove the countershaft bearing cup and shim.
2. Remove the input shaft bearing cup and shim.
3. Remove the input shaft seal.
^ Carefully pry out from the inside of the case.





54. Remove the rear countershaft bearing.





55. Remove the rear countershaft bearing cup and the rear output shaft bearing cup.