Tools Required
• | J 36509 Detent Spring Plug
Remover |
• | J 36511 Oil Fill and Drain
Plug Hex Bit - 17 mm |
• | J 36825 Output Shaft Oil
Seal Remover |
Important: The transmission must remain in 3rd or 5th gear in order to prevent
losing the shift shaft lever spring and plunger.
- Using the J 36511
, remove the oil
fill plug.
- If the transmission is not in 3rd or 5th gear, reinstall the shift
control housing and shift the transmission in 3rd or 5th gear.
- Place a suitable container under the
transmission assembly in order to drain the remaining transmission fluid.
- Using J 36511
, remove the
oil drain plug.
- Remove the gasket material from the housing.
- Remove the 2 reverse idler gear
shaft support bolts.
- Remove the back-up lamp switch.
- If 2WD, remove the vehicle speed sensor
and O-ring.
- Remove the shift shaft detent pin.
- Using the J 36509
(1)
and the J 23907
(2), remove the
detent plug, spring, and detent plunger.
- If 4WD vehicle, remove the output shaft
seal using the J 36825
and the J 23907
. Screw the J 36825
into 1 of the 3 perforated holes in the seal.
- Remove the 6 bolts securing the
input shaft bearing retainer to the clutch housing.
Remove the
retainer by screwing 2 of the removed bolts into the threaded holes
in the retainer.
- Remove the input shaft bearing retainer
ring.
- Remove the bolts securing the clutch
housing to the rear case.
Notice: Do not nick, scratch or damage the sealing surface. The
sealing surface is a machined surface. Damage to the machined surface can
cause leakage.
- Separate
the clutch housing from the rear case using a soft-face hammer. Do not pry
at the sealing surfaces.
- Remove the countershaft front bearing.
- Move the reverse idler gear shaft towards
the countershaft.
- Remove the reverse idler gear shaft support.
Important: If the shift rail is rotated, the shift lever spring and plunger may
come out of the shift shaft lever.
- Slowly shift the transmission in neutral.
- Rotate the shift rail counterclockwise. While rotating, catch
the shift shaft plunger and the shift shaft spring.
- Remove the shift shaft lever roll pin.
21.1. | Rotate the shift shaft lever finger down. |
21.2. | Support the shift shaft end. |
21.3. | Drive out the roll pin. |
21.4. | Ensure that the roll pin clears the 2nd speed gear. |
- Remove the shift shaft socket roll pin.
22.1. | Align the shift shaft socket in the center of the case opening. |
22.2. | Using a 5 mm (3/16 in) punch, remove the roll pin. |
- Remove the following components:
23.2. | The shift shaft socket |
23.3. | The shift shaft lever |
23.4. | The shift shaft block out bushing |
- Rotate the 3rd/4th speed gear shift fork
counterclockwise.
- Remove the 3rd/4th speed gear shift fork from the transmission
case.
- If 2WD vehicle, loosen the 3 bolts
on the rear of the housing. Do not remove the bolts.
- Install the J 36515-15
(3)
on the input shaft.
- Install the J 36515-16
(1)
on the countershaft.
- Install the transmission to the J 36515
(2).
- Adjust the reverse holding pin against the reverse gear idler
shaft.
- If 2WD vehicle, remove the 3 bolts
on the rear of the housing.
- If 4WD vehicle, remove the main shaft
rear bearing retaining ring.
- Remove the rear housing, 4WD shown. Tap
the rear housing with a rubber mallet.