Disassemble

Gears & Shaft Components:

1. Drain lubricant from transmission, then remove fork and release bearing from clutch housing.
2. Remove 6 front cover attaching bolts, then the front cover, shim and gasket.

Front Cover Oil Seal Removal:

3. Remove front cover oil seal, then the input shaft snap ring.
4. Remove outer snap ring from input shaft bearing.

Input Shaft Bearing Removal Tool Installation:

Input Shaft Bearing Removal:

5. Remove input, shaft bearing.
6. Remove 8 extension housing-to-transmission case attaching bolts, then slide housing off mainshaft with control lever end laid down and to the left as far as possible.
7. Remove control lever end attaching bolt, then the control lever end and rod from extension housing.
8. Remove speedometer driven gear assembly from extension housing.
9. Remove back-up lamp and neutral sensing switches from extension housing.
10. On models equipped with speed control, remove speed control sensor retaining bolt, then the speed sensor and speedometer drive gear.
11. On models less speed control, remove speedometer drive gear snap ring, then the drive gear and lock ball.

Countershaft & Front Bearing Removal:

12. Separate bearing housing from transmission case, then remove countershaft gear assembly and bearing housing from case.

Shift Lock Ball & Spring Removal:

13. Remove 3 spring cap screws, springs and balls.

WARNING: Personal injury may result if case is not used when removing the spring-loaded lower ball.

14. Remove reverse shift rod and shift fork assembly, and reverse gear from bearing housing.
15. Drive out shift fork roll pins, then remove shift forks and rods. Mark shift forks so they can be installed in their original positions.
16. Remove lower reverse shift rod locking bolt and spring and the interlock pins from bearing housing.

Mainshaft Locknut Removal:

17. Bend down tab on mainshaft lockwasher, then lock transmission synchronizers into any 2 gears and remove mainshaft locknut.
18. Remove reverse gear and key from mainshaft.
19. Remove counter reverse gear snap ring and the gear.
20. Remove 5 bearing cover attaching bolts, then the bearing cover and reverse idler gear shaft from bearing housing.
21. Tap mainshaft and countershaft out of bearing housing using a soft-faced hammer.

Exploded View Of Shafts & Gears:

22. Remove input shaft and roller bearing from mainshaft.
23. Remove rear countershaft bearing from bearing housing using tool T77J-7025-B or equivalent.
24. Remove rear mainshaft bearing from bearing housing using tools T77F-4222-A and T77J-7025-B or equivalents.
25. Remove thrust washer, first gear, sleeve and synchronizer ring from rear of mainshaft.
26. Remove mainshaft snap ring.
27. Remove 3rd-4th clutch hub, sleeve, synchronizer ring and 3rd gear from front of mainshaft using a suitable press and tool No. T71P-4621-B or equivalent.
28. Remove 1st-2nd clutch hub, sleeve and 2nd gear from rear of mainshaft using a suitable press and tool No. T71P-4621-B or equivalent.

Countershaft Front Bearing Removal:

29. Press front bearing out of countershaft.