Gear Components
1. Before disassembly, measure the end play of each gear.
- If end play is not within the specified limit, disassemble and inspect the parts.
- Replace any part which is worn or damaged. Refer to the illustration for gear end play specifications.
2. Mesh 2nd and reverse gear, then remove countershaft front bearing using a suitable puller.
3. Remove snap ring, then remove sub-gear bracket, sub-gear spring and sub-gear.
4. Remove counter drive gear together with main drive gear assembly using a suitable puller.
- When removing main drive gear assembly, be careful not to drop pilot bearing or baulk ring. Remove snap ring, then remove 3rd & 4th synchronizer assembly and 3rd main gear.
6. Disassemble parts at rear of adapter plate as follows:
a. Release staking on both countershaft and mainshaft nuts, then loosen both nuts.
- Mainshaft nut: Lefthand thread
b. Remove overdrive counter gear together with countershaft rear end bearing using a suitable puller.
c. Remove reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, then remove reverse idler gear, thrust washers and reverse idler gear bearing.
e. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring.
f. Remove mainshaft nut.
g. Remove speedometer drive gear and steel ball.
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove overdrive main gear, needle bearing and baulk ring (overdrive).
j. Remove counter gear by tapping on rear end of counter gear.
k. Press out overdrive gear bushing and overdrive & reverse synchronizer assembly.
l. Remove reverse main gear and needle bearing.
m. Press out reverse gear bushing.
7. Remove thrust washer, steel ball, 1st main gear and needle bearing.
- Be careful not to lose steel ball.
8. Press out 1st gear bushing together with 2nd main gear using Tool. Remove 2nd gear needle bearing.
9. Remove main drive gear ball bearing.
a. Remove snap ring.
b. Remove main drive gear ball bearing.