Transmission Disassembly
- Remove transmission drain plug and drain transmission. Remove top cover assembly and extension housing. Remove speedometer drive gear and steel ball (if equipped). If necessary, remove rear oil passage.
- Lock transmission into 1st and 3rd gears. Release staked areas securing output shaft and countershaft lock nuts. Remove and discard countershaft rear bearing lock nut. Remove countershaft rear bearing and thrust washer.
- Remove and discard output shaft lock nut. Remove reverse idler shaft fixing bolt. See Fig 1. Remove reverse idler gear assembly by grasping and pulling rearward. Remove output shaft rear bearing from output shaft using Remover/Replacer Tube (T75L-7025-B), TOD Forcing Screw (T84T-7025-B) and Bearing Puller (T77J-7025-H).
- Using brass drift and hammer, drive reverse gear from output shaft. Remove output shaft sleeve. See Fig 2. Remove countershaft reverse gear with 2 needle bearings and reverse synchronizer ring.
- Remove thrust washer and split washer from countershaft. Remove 5th and reverse shift rod fixing bolt.
- Remove the following parts as an assembly: 5th-reverse synchronizer hub and sleeve assembly (countershaft), 5th-reverse shift fork and rod. DO NOT separate steel ball and spring (removed from shift fork groove) unless necessary.
- Remove 5th gear synchronizer ring, 5th-reverse counter lever lock plate bolt, inner circlip and counter lever assembly from transmission case. DO NOT remove Torx nut retaining counter lever pin at this time. Remove countershaft 5th gear with needle bearing.
- Remove output shaft 5th gear using Bearing Collet (for 3 1/2" bearing), Gear Removal Collet Assembly (T75-7025-G and T88-T7061-A) and Remover/Replacer Tube (T85T-7025-A) with TOD Forcing Screw (T84T-7025-B). Remove 5th gear sleeve and Woodruff key or lock ball. Remove center and front bearing cover bolts.
- To remove front bearing cover, thread 2 bolts into front bearing cover bolt locations at 9 and 3 o'clock positions. Alternately tighten bolts until bolts bottom out and lift front bearing cover away from transmission case. DO NOT remove plastic scoop ring from input shaft at this time.
- Remove oil trough from upper transmission case by removing bolt. See Fig 3. Pull input shaft forward and remove input shaft bearing outer race. Pull output shaft rearward.
- Pull input shaft forward and separate it from output shaft assembly. Incline output shaft upward and lift from transmission case. Remove input shaft from transmission case.
- Remove countershaft front and center bearing outer races by moving countershaft forward and rearward. Pull countershaft rearward to permit clearance for bearing puller behind countershaft front bearing. Remove countershaft front bearing. Remove countershaft through top of transmission case.
LEGEND FOR FIGURE NO. 2
| Item No. | Description |
|---|---|
| 1 | Lock Nut (Output Shaft) |
| 2 | Lock Nut (Countershaft) |
| 3 | Countershaft Rear Bearing |
| 4 | Thrust Washer |
| 5 | Fixing Bolt (Reverse Idler Gear) |
| 6 | Reverse Idler Gear Assembly |
| 7 | Bearing (Rear Output Shaft) |
| 8 | Reverse Gear (Output Shaft) |
| 9 | Sleeve-Output Shaft |
| 10 | Countershaft Reverse Gear |
| 11 | Needle Bearing |
| 12 | Synchronizer Ring (Reverse) |
| 13 | Thrust Washer |
| 14 | Split Washer (2 pcs.) |
| 15 | Fixing Bolt (Shift Rod) |
| 16 | Shift Rail Fork Hub/Sleeve Assy. |
| 17 | Lock Ball (Shift Rail) |
| 18 | Spring (Shift Rail) |
| 19 | Synchronizing Ring (5th Gear) |
| 20 | 5th Gear (Output Shaft) |
| 21 | 5th Gear (Countershaft) |
| 22 | Needle Bearing (5th Gear) |
| 23 | Sleeve (5th Gear) |
| 24 | Woodruff Key or Lock Ball |
| 25 | Center Bearing Cover |
| 26 | 5th-Reverse Counter Lever Lock Plate Bolt |