Transmission Disassemble NV3500

Tools Required

1. Remove 2 reverse idler shaft support bolts.



2. Remove 2 lower-housing bolts. Tool J 3289-20 must be mounted securely on a sturdy workbench.



3. Assemble the transmission holding fixture:

3.1.	The J 8763-21 onto the J 8763-02

3.2.	The J 36824 onto the transmission housing

3.3.	The J 8763-02 onto the J 36824

3.4.	The J 8763-02 onto the J 3289-20




4. Remove the backup lamp switch assembly.



5. Remove the shift shaft block-out bushing pin.



6. Remove the following components:

6.1.

The bolt

6.2.	The vehicle speed sensor




7. Complete the following tasks:

7.1.	Remove the detent plug. Use the J 36509 and the J 23907 .

7.2.	Remove the detent spring and the detent plunger.

8. Remove the concentric slave cylinder.



9. Position the transmission vertically. Scribe the retainer and the case to aid in ensuring proper position during reassembly. Remove the following components:

9.1.	The 6 bolts

9.2.	The input shaft bearing retainer

10. Remove the retainer by screwing two of the removed bolts into the threaded holes provided. Press off the retainer.
11. Tap the clutch release bearing pilot with a rubber mallet.



12. Remove the input shaft snap ring.



13. Position the transmission horizontally.

Remove the front housing to the rear housing bolts.





Important: Support the front housing. Do not allow the front housing to fall.

14. Drive the 2 dowel pins into the front housing.



15. Remove the front housing.



16. Remove the countershaft bearing.



17. Remove the reverse idler shaft support. The idler shaft support will snap out.



18. Move all of the shift forks forward. Engage the 4th gear, the 2nd gear, and Reverse gear. Retain the shift lever detent plunger and spring.



19. Remove the shift shaft lever roll pin.

19.1.

Rotate the shift shaft lever finger down.

19.2.

Support the shift shaft end.

19.3.

Drive out the roll pin.

19.4.

Ensure that the roll pin clears the 2nd speed gear.




20. Shift all of the gears into neutral.



21. Engage the 5th speed gear.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.




22. Push the shift shaft into the housing.



23. Remove the shift shaft socket roll pin.

23.1.

Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.

23.2.

Support the shift shaft end.

23.3.

Drive out the roll pin. Use a 5 mm (3/16 in) punch. The roll pin will fall into the transmission housing.




24. Remove the following components:

24.1.

The shift shaft

24.2.

The shift shaft socket

24.3.

The shift shaft lever

24.4.

The shift shaft block-out bushing




25. Remove the 3rd/4th speed gear shift fork. Rotate counterclockwise



26. Loosen 3 bolts on the rear of the housing. Do not remove the bolts.



27. Install the tool J 36515-15 on the input shaft.
28. Install the tool J 36515-16 on the countershaft.
29. Install the tool J 36515 to the transmission assembly.
30. Place the unit fixture on the bench while holding the J 36515 fixture assembly on the transmission assembly.



31. Remove tools J 8763-02 and J 36824 from the transmission housing.



32. Remove the 3 bolts from the rear housing.



33. Remove the rear housing. Tap the rear housing with a rubber mallet.



34. Remove the mainshaft bearing retainer.



35. Remove the following components:

35.1.

2 shift forks (1)

35.2.

The reverse idler gear (2)

36. Partially lift the mainshaft to allow removal of the countershaft. Remove the following components:

36.1.

The countershaft (3)

36.2.

The countershaft bearing (4)




37. Remove the vehicle speed sensor reluctor wheel. Use the J 21427-A and the J 24420-B . Discard the reluctor wheel.



38. Remove the following components:

•	The rear mainshaft bearing snap ring (1)

•	The rear mainshaft bearing (2)




39. Remove the mainshaft assembly from the assembly pallet J 36515 . Remove the following parts:

•	The input shaft

•	The mainshaft pilot bearing from the input shaft

Transmission Disassemble Two Wheel Drive

Tools Required

1. Remove 2 reverse idler shaft support bolts.



2. Remove 2 lower-housing bolts. Tool J 3289-20 must be mounted securely on a sturdy workbench.



3. Assemble the transmission holding fixture:

3.1.	The J 8763-21 onto the J 8763-02

3.2.	The J 36824 onto the transmission housing

3.3.	The J 8763-02 onto the J 36824

3.4.	The J 8763-02 onto the J 3289-20




4. Remove the backup lamp switch assembly.



5. Remove the shift shaft block-out bushing pin.



6. Remove the following components:

6.1.

The bolt

6.2.	The vehicle speed sensor




7. Complete the following tasks:

7.1.	Remove the detent plug. Use the J 36509 and the J 23907 .

7.2.	Remove the detent spring and the detent plunger.

8. Remove the concentric slave cylinder.



9. Position the transmission vertically. Scribe the retainer and the case to aid in ensuring proper position during reassembly. Remove the following components:

9.1.	The 6 bolts

9.2.	The input shaft bearing retainer

10. Remove the retainer by screwing two of the removed bolts into the threaded holes provided. Press off the retainer.
11. Tap the clutch release bearing pilot with a rubber mallet.



12. Remove the input shaft snap ring.



13. Position the transmission horizontally.

Remove the front housing to the rear housing bolts.





Important: Support the front housing. Do not allow the front housing to fall.

14. Drive the 2 dowel pins into the front housing.



15. Remove the front housing.



16. Remove the countershaft bearing.



17. Remove the reverse idler shaft support. The idler shaft support will snap out.



18. Move all of the shift forks forward. Engage the 4th gear, the 2nd gear, and Reverse gear. Retain the shift lever detent plunger and spring.



19. Remove the shift shaft lever roll pin.

19.1.

Rotate the shift shaft lever finger down.

19.2.

Support the shift shaft end.

19.3.

Drive out the roll pin.

19.4.

Ensure that the roll pin clears the 2nd speed gear.




20. Shift all of the gears into neutral.



21. Engage the 5th speed gear.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.




22. Push the shift shaft into the housing.



23. Remove the shift shaft socket roll pin.

23.1.

Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.

23.2.

Support the shift shaft end.

23.3.

Drive out the roll pin. Use a 5 mm (3/16 in) punch. The roll pin will fall into the transmission housing.




24. Remove the following components:

24.1.

The shift shaft

24.2.

The shift shaft socket

24.3.

The shift shaft lever

24.4.

The shift shaft block-out bushing




25. Remove the 3rd/4th speed gear shift fork. Rotate counterclockwise



26. Loosen 3 bolts on the rear of the housing. Do not remove the bolts.



27. Install the tool J 36515-15 on the input shaft.
28. Install the tool J 36515-16 on the countershaft.
29. Install the tool J 36515 to the transmission assembly.
30. Place the unit fixture on the bench while holding the J 36515 fixture assembly on the transmission assembly.



31. Remove tools J 8763-02 and J 36824 from the transmission housing.



32. Remove the 3 bolts from the rear housing.



33. Remove the rear housing. Tap the rear housing with a rubber mallet.



34. Remove the mainshaft bearing retainer.



35. Remove the following components:

35.1.

2 shift forks (1)

35.2.

The reverse idler gear (2)

36. Partially lift the mainshaft to allow removal of the countershaft. Remove the following components:

36.1.

The countershaft (3)

36.2.

The countershaft bearing (4)




37. Remove the vehicle speed sensor reluctor wheel. Use the J 21427-A and the J 24420-B . Discard the reluctor wheel.



38. Remove the following components:

•	The rear mainshaft bearing snap ring (1)

•	The rear mainshaft bearing (2)




39. Remove the mainshaft assembly from the assembly pallet J 36515 . Remove the following parts:

•	The input shaft

•	The mainshaft pilot bearing from the input shaft

Transmission Disassemble Four Wheel Drive

Tools Required

1. Remove the two reverse idler shaft support bolts



2. Remove two housing bolts



3. Assemble the transmission holding fixture:

3.1.	J 8763-21 onto J 8763-02

3.2.	J 36824 onto the transmission housing

3.3.	J 8763-02 onto J 36824

3.4.	J 8763-02 onto J 3289-20

3.5.	Mount tool J 3289-20 securely on a sturdy workbench.




4. Remove the backup lamp switch assembly.



5. Remove the shift shaft block-out bushing pin.



6. Remove the following components:

6.1.	The detent plug. Use J 36509 and J 23907 .

6.2.	The detent spring

6.3.	The detent plunger




7. Remove the output shaft oil seal. Use J 36825 and J 23907 .

Use J 36825 by screwing it into one of the three perforated holes in the seal.




8. Position the transmission vertically. Remove the following components:

8.1.	The 6 bolts

8.2.	The input shaft bearing retainer

8.3.	Tap the clutch release bearing pilot with a rubber mallet.




9. Remove the input shaft snap ring.



10. Position the transmission horizontally. Remove the front housing to the rear housing bolts.



11. Drive the 2 dowel pins into the front housing.



12. Remove the front housing.



13. Remove the countershaft bearing.



14. Remove the reverse idler shaft support. The idler shaft support will snap out.



15. Move all the shift forks forward. Engage 4th gear, 2nd gear, and Reverse gear. Retain the shift lever detent plunger and spring.



16. Remove the shift shaft lever roll pin.

16.1.

Rotate the shift shaft lever finger down.

16.2.

Support the shift shaft end.

16.3.

Drive out the roll pin.

16.4.

Ensure the roll pin clears the 2nd speed gear.




17. Shift all the gears into neutral.



18. Engage the 5th speed gear.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.




19. Push the shift shaft into the housing.



20. Remove the shift shaft socket roll pin.

20.1.

Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.

20.2.

Support the shift shaft end.

20.3.

Drive out the roll pin. Use a 5 mm (3/16 in) punch.

20.4.

The roll pin will fall into the transmission housing.




21. Remove the following components:

21.1.

The shift shaft

21.2.

The shift shaft socket

21.3.

The shift shaft lever

21.4.

The shift shaft block-out bushing




22. Remove the 3rd/4th speed gear shift fork. Rotate counterclockwise



23. Install tool J 36515-15 on the input shaft.
24. Install tool J 36515-16 on the countershaft.
25. Install J 36515 to the transmission assembly with the adapters and transmission assembly upright on the work bench.



26. Remove J 8763-02 and J 36824 from the transmission housing.



27. Remove the mainshaft bearing snap ring.



28. Remove the rear housing. Tap the rear housing with a rubber mallet.



29. Remove the following components:

29.1.

Two shift forks (1)

29.2.

The reverse idler gear (2)

29.3.

The countershaft (3)

29.4.

The countershaft bearing (4)




30. Remove the mainshaft assembly from the assembly pallet J 36515 . Remove the following parts:

•	The input shaft

•	The mainshaft pilot bearing from the input shaft