Part 1

DISASSEMBLY

Special Tools:


























1. Hold the output flange (3) with Special Tool (2) Flange Wrench while removing the output flange locknut.
2. Remove the output flange from the transmission output shaft.





3. Remove shift cover (1) bolts (2) and remove cover.





4. Remove offset lever (1) roll pin (2) with a hammer and punch.





5. Remove offset lever (1) from shift rail (2).





6. Remove extension housing (1) nuts (2) from transmission studs.





7. Remove extension housing (1) bolts (2).





8. Pry extension housing (1) off transmission case (2) at pry points.





9. Stand transmission on Fixture and bolt adapter to fixture.
10. Install on bench Fixture.
11. Remove mainshaft roller bearing (2) snap ring (1).





12. Remove mainshaft roller bearing (1) and spacers (2) from mainshaft.





13. Remove reverse gear (1) snap ring (2) from mainshaft.





14. Remove reverse gear (1) thrust washer (2) from mainshaft.





15. Remove reverse gear (1) from mainshaft (2).





16. Remove reverse gear bearing (1) from mainshaft (2).





17. Remove reverse synchronizer rings (1) from reverse synchronizer hub.





18. Remove reverse synchronizer hub (1) snap ring (2) from mainshaft.





19. Remove reverse shift fork (1) snap ring (2) from shift rail and discard snap ring.





20. Remove reverse shift fork (1) synchronizer hub and sleeve as an assembly (2).





21. Remove reverse gear (1) snap ring (2) from countershaft.





22. Remove reverse gear from countershaft (1) with three jaw puller (2) and Button.





23. Remove fifth gear snap ring (1) from countershaft (2).





24. Remove fifth gear thrust washer (1) from countershaft (2).





25. Remove fifth gear (1) from countershaft (2).





26. Remove fifth gear bearing (1) from countershaft (2).





27. Remove fifth gear bearing spacer (1) from countershaft (2).





28. Remove fifth gear synchronizer rings (1) from 5-6 synchronizer hub (2).





29. Remove fifth gear split ring retainer (1) from mainshaft (2).





30. Remove fifth gear split rings (1) from mainshaft (2).





31. Remove fifth gear (4) from mainshaft with Bridge (1) Bolts (2) Puller (3) and Button.





32. Remove 5-6 gear shift fork snap ring (1) from shift rail (2).





33. Remove 5-6 synchronizer hub snap ring (1) from countershaft.





34. Remove 5-6 shift fork (1) synchronizer sleeve (2) and detentes (3) from 5-6 synchronizer hub.





35. Remove 5-6 synchronizer hub from countershaft with Bridge (1) Bolts (2) Puller (3) and Button.





36. Remove sixth gear synchronizer rings (1) from sixth gear (2).





37. Remove sixth gear (1) from countershaft (2).





38. Remove sixth gear bearing (1) from countershaft (2).





39. Remove sixth gear bearing spacer (1) from countershaft (2).





40. Remove top cover (1) bolts and remove cover from transmission case (2).





41. Remove shift detent (1) from right side of case (2).





42. Remove skip shift solenoid (1) from left side of case (2).