Important: The following steps apply to both the 4WD and the RWD transmission,
except where noted.
- Remove the drain plug, with aluminum washer, and drain the transmission
fluid.
- If RWD, remove the vehicle
speed sensor with O-ring seal.
- Remove the backup lamp switch, with the aluminum washer, from the front
case.
- Remove the 9 bolts retaining the clutch housing.
- Using a soft-face hammer, remove the clutch housing from
the transmission assembly.
- Shift the transmission into NEUTRAL.
- Remove the shift control housing bolts.
- Remove the shift control housing.
- Remove the shift control housing gasket.
- Remove the shift control
lever socket bolt.
- Mark the location of the
brackets and the studs.
- Remove the extension housing retaining bolts, studs, and brackets.
The 4WD does not use a bracket on the left side of the transmission.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Using a soft-face hammer, separate the extension housing from
the intermediate case.
- Slide the extension housing off the shift control shaft.
- Remove the shift control socket from the extension housing shift
lever cavity.
- Remove the shift control shaft from the shift shaft gates.
- Remove the front bearing
retainer bolts. Discard the bolts. New bolts are required for assembly.
- Remove the front bearing retainer.
- Using a suitable punch
and a hammer, remove the input shaft seal from the bearing retainer. Do not
use the seal again.
- Remove the outer retaining ring from the input shaft bearing.
- Remove the outer retaining ring from the countershaft front bearing.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Using a soft-face hammer on the transmission front case, shear
the sealer.
- Remove the transmission front case from the intermediate case.
- Remove the oil baffle
bolts.
- Remove the oil baffle.
- Remove the magnet.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Install 2 bolts, with nuts, in the lower holes of the intermediate
case. The bolts will be used to hold the intermediate case in a vise during
disassembly and assembly.
Important: Before removal of the 5th synchronizer gear, measure the axial play
of the speed gear. Incorrect axial play of the gear may cause shifting concerns
or transmission noise.
- Using a feeler gage between the 5th countershaft gear and the thrust
washer, measure the axial clearance.
Specification
• | Standard Clearance: 0.10-0.35 mm (0.0039-0.0138 in) |
• | Maximum Clearance: 0.40 mm (0.0157 in) |
- If the clearance exceeds the maximum, refer to
Gears and Shafts Cleaning and Inspection
.
- Mount the intermediate
case assembly in a vise on the 2 previously installed bolts.
- Using 2 screwdrivers and a hammer, remove the 5th synchronizer
gear retaining ring.
- Using J 8433
with
2 bolts in the threaded holes of the 5th synchronizer gear, remove
the gear.
- Using a hammer and a punch,
remove the 5th shift fork roll pin.
- Remove the 5th/reverse
synchronizer sleeve and blocking ring assembly with the 5th shift fork.
- Remove the 5th/reverse synchronizer sleeve and blocking ring assembly
from the shift fork.
- Remove the 5th countershaft
gear, with bearing, from the countershaft.
- Remove the 5th countershaft
gear thrust washer.
- Remove the thrust washer lock pin.
- Remove the bolts for the rear bearing retainer.
- Remove the rear bearing retainer.
- Using a soft-face
hammer, tap the countershaft rearward to expose the outer retaining ring on
the countershaft rear bearing.
- Using a suitable prying tool on the retaining ring, remove the
countershaft rear bearing. The bearing will slide out of the case if the
countershaft is kept in position with the output shaft.
- Remove the countershaft.
- Remove the reverse idler
gear shaft and reverse idler gear.
- Remove the input shaft
assembly, with the 4th gear blocking ring, and output shaft front support
bearing from the output shaft.
- Remove the 1st/2nd shift fork bolt.
- Remove the 3rd/4th shift fork bolt.
- Remove the retaining ring
for the reverse shift lever on the reverse shift shaft.
• | Use a suitable pair of pliers to push the retaining ring. |
• | Only push the retaining ring partially off to keep it from flying. |
• | Use a pair of pliers to remove the retaining ring the rest of
the way. |
- Shift the reverse shift
shaft forward.
- Move the reverse shift lever forward past the retaining ring
groove on the reverse shift shaft. This allows clearance of the reverse shift
fork during removal of the output shaft.
- Remove the output shaft
rear bearing outer retaining ring.
- Remove the output shaft assembly.
• | Hold the 1st/2nd shift fork and the 3rd/4th shift fork in position
to the output shaft. |
• | Slide the 1st/2nd shift fork and the 3rd/4th shift fork off the
shift shafts while removing the output shaft. |
Important: If the shift shafts or the intermediate case do not require service,
proceed to Output Shaft Disassemble. If the shift shafts or intermediate
case require service, proceed to the next step.
- Remove the 4 shift shaft detent plugs for the shift detent balls
and springs. Discard the plugs. New plugs are required for assembly.
- Using a magnet, remove
the 1st/2nd shift shaft detent spring and ball.
- Using a magnet, remove the 3rd/4th shift shaft detent spring and
ball.
- Using a magnet, remove the 5th shift shaft detent spring and ball.
The reverse shift shaft does not have a detent spring and ball in the plug
opening.
Important: To prevent the retaining rings from flying, cover the area with a rag.
- Remove the following shift shaft retaining rings:
• | The 1st/2nd shift shaft |
• | The 3rd/4th shift shaft |
- | Use a suitable pair of pliers to push the retaining ring. |
- | Only push the retaining ring partially off to keep it from flying. |
- | Use a pair of pliers to remove the retaining ring the rest of
the way. |
- Remove the 3rd/4th shift shaft.
- Using a magnet, remove the 1st/2nd and 3rd/4th shift shaft interlock
pin.
- Remove the 1st/2nd shift shaft.
- Remove the small interlock pin from the 1st/2nd shift shaft.
- Using a magnet, remove the 5th shift shaft and 1st/2nd shift shaft interlock
pin.
- Remove the 5th shift shaft.
- Remove the detent ball
from the reverse shift lever.
- Remove the reverse shift
lever, with the reverse shift fork, from the reverse shift shaft.
65.1. | Slide the shift lever to the end of the shaft. |
65.2. | Cover the detent ball opening with your hand. |
65.3. | Let the detent ball and spring land in your hand. |
- Using a magnet, remove the interlock pin from the reverse shift shaft.
The shaft may require moving back and forth to remove the interlock pin.
- Remove the reverse shift shaft.
- Remove the bolts and the
reverse shift fork bracket.