Tools Required

1. Remove the two bolts which attach the idler shaft segment and the idler shaft support collar to the rear housing.
2. Remove the backup lamp switch from the rear housing.
3. Remove the electronic speed sensor from the rear housing.
4. Remove the shift shaft block-out bushing pin from the front housing.



5. Using the J 36509 in the detent plug and the J 23907 remove the following components from the front housing:

•	The detent plug

•	The spring

•	The plunger




6. Remove the five bolts which secure the input shaft bearing retainer to the front housing.
7. Use the J 23907 to remove the input shaft bearing retainer from the front housing.
8. Remove the snap ring.



9. Remove the nine bolts securing the front housing to the rear housing.
10. Angle the front housing up and press down on the rear housing in order to separate the front housing from the rear housing.
11. Remove the countershaft roller bearing from the countershaft or the bearing shell.



12. Remove the shift shaft lever roll pin from the shift shaft lever:

•	Rotate the shift shaft lever and the shift shaft bushing.

Important: Do not lose the shift shaft lever plunger or the spring when removing the shift shaft lever roll pin from the rear housing.

•	Remove the shift shaft lever plunger and the spring.

•	Support the shift shaft end while driving out the shift shaft lever roll pin.

•	Allow the roll pin to clear the second gear during removal.

Important: 

•	Do not bend the shift rail when removing the roll pin.

•	Use a 5 mm (3/16 inch) drift punch in order to remove the roll pin.

•	The roll pin will fall into the rear housing.

13. Remove the shift shaft socket roll pin from the bottom of the shift shaft socket.



14. Remove the following components:

•	The shift shaft

•	The shift shaft socket

•

The lever

•	The shift shaft block-out bushing

15. Rotate the third-fourth shift fork counterclockwise.

Remove the third-fourth shift fork.




16. Remove the bolts (1,2,3,4,5) securing the output shaft bearing retainer to the center of the rear housing.
17. Remove the rear housing from the gear assemblies.
18. Remove the reverse idler gear assembly.
19. Remove the output shaft bearing retainer.
20. Remove the shift forks.
21. Remove the countershaft.
22. Remove the countershaft bearing snap ring.
23. Remove the countershaft bearing.

The countershaft bearing must be pressed off the counter shaft.

24. Remove the fifth counter gear from the counter shaft.



25. Use the J 21427-A and the J 24420-C in order to remove the speed sensor rotor from the output shaft.
26. Remove the snap ring from the output shaft.
27. Use the J 21427-A and the J 24420-C in order to remove the output shaft bearing from the output shaft.




Important: When removing the fifth reverse synchronizer from the main shaft, do not let the synchronizer retaining rings slide away from the sides of the fifth-reverse synchronizer assembly. If the synchronizer retaining rings are moved, the springs, detent balls and ball retainers will pop out of the synchronizer.

Important: The first and fifth gear blocking rings look the same, but are not interchangeable with the reverse blocker ring. Prior to removing the reverse gear blocking ring from the main shaft, mark the reverse gear blocking ring for installation identification.

28. Remove the following components from the output end of the main shaft:

28.1.

The fifth gear

28.2.

The snap ring

28.3.

The synchronizer blocking ring

28.4.

The fifth reverse synchronizer

28.5.

The synchronizer blocking ring

28.6.

The reverse gear




29. If the fifth reverse synchronizer was disassembled, assemble the synchronizer as shown.



30. Remove the input shaft and the pocket bearing from the input end of the main shaft.



31. Remove the snap ring.
32. Use a hydraulic press in order to remove the following components from the main shaft:

•	The third-fourth gear synchronizer blocking ring

•	The third-fourth gear synchronizer

•	The third-fourth gear synchronizer blocking ring

•	The third gear




33. Remove the following components from the main shaft:

•	The two piece split washer, pin, and retaining ring

•	The second gear

•	The inner cone

•	The middle cone

•	The second gear synchronizer blocking ring.




34. Use J 21427-A and J 24420-C to remove the second gear from the main shaft.




Important: When removing the fifth reverse synchronizer from the main shaft, do not let the synchronizer retaining rings slide away from the sides of the fifth-reverse synchronizer assembly. If the synchronizer retaining rings are moved, the springs, detent balls and ball retainers will pop out of the synchronizer.

Important: Scribe the synchronizer hub to the output shaft prior to disassembly.

35. Use the J 22912-01 and a hydraulic press to remove the following components from the main shaft:

•	The snap ring

•	The first and second gear synchronizer assembly

•	The first gear synchronizer blocking ring

•	The middle cone

•	The inner cone

•	The first gear




36. If the fifth reverse synchronizer was disassembled, assemble the synchronizer as shown.



37. Remove the following components from the reverse idler shaft:

•	The segment

•

The gear

•	The bearing assembly

•	The collar

•	The two o-rings from the shaft




38. Use the J 23907 and J 36800 in order to remove the front shift rail bushing from the front housing.
39. Remove the input shaft bearing from the front housing.




Important: During the removal of the shift shaft rail rear bushing, if the bushing lip breaks off, position the puller legs behind the inside (outer edge) of the lip and repeat the removal procedure.

40. Use the J 23907 in order to remove the rear shift rail bushing from the rear housing.

•	Position the puller legs behind the bearing lip.

•	Tighten the puller legs.

•	Pull with the slide hammer in order to remover the bushing.




41. Use the J 26941 and J 23907 in order to remove the slip yoke oil seal



42. Use the J 36511 in order to remove the oil fill plug.



43. Use the J 36511 in order to remove the oil drain plug.
44. Remove all existing gasket material from the transmission housing.