Gear Components

1. Before disassembly, measure each gear end play.
- If end play is not within the specified limit, disassemble and check the parts.
- Replace any part which is worn or damaged.

2. Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, sub-gear spring and sub-gear.

4. Draw out counter drive gear with main drive gear assembly with suitable puller.

Note: When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring.

5. Disassemble parts at rear of adapter plate as follows.
a. Release staking on countershaft nut and mainshaft nut and loosen these nuts.
Main shaft nut: Left-hand thread

b. Pull out O.D. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, and draw out reverse idler gear, thrust washers and reverse idler gear bearing.
e. Remove speedometer drive gear and steel bail.

f. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring.
g. Remove mainshaft nut.
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove O.D. main gear, needle bearing and baulk ring (O.D.).
j. Remove O.D. coupling sleeve, shifting inserts and shifting insert springs.

k. Press out mainshaft and counter gear alternately.

Note: Make sure to alternate pressing of mainshaft and counter gear. So as not to allow the front surface of one to contact the rear surface of the other.

6. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.

c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.

7. Remove main drive gear bearing.
a. Remove snap ring and washer.
b. Remove main drive gear bearing.