Transmission

Special Tool(s)

	2 Jaw Puller 205-D026 (D80L-1002-L) or equivalent
	2 or 3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent
	Handle 205-153 (T80T-4000-W)
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Holding Tool, Drive Pinion Flange 205-478
	Holding Tool, Rear Flange 308-807
	Installer, Shift Rail Needle Bearing 308-130 (T87T-7025-DH)
	Remover, Detent 308-812
	Push/Puller Set 205-DS023 (D80L-927-A) or equivalent
	Remover, Input Shaft Oil Seal 308-375
	Remover, Synchro Gear Pack 308-810
	Slide Hammer 100-001 (T50T-100-A)
	Step Plate 205-D013 (D80L-630-2) or equivalent

 WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTE: For additional information on component views and base part numbers, refer to Transmission in this section.

1. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.

2. Attach the transmission to the Transmission Holding Fixture.

3. Remove the clutch slave cylinder and if equipped, the clutch slave cylinder spacer.
   1. Remove the 2 clutch slave cylinder bolts.
   2. Pull the clutch slave cylinder outward and release the tube from the retaining clip.

4. Inspect the clutch slave cylinder for the following:
   • Damaged boot
   • Leaking brake fluid
   • Worn or damaged release bearing
     • Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder.

5. Using the Input Shaft Oil Seal Remover and the Slide Hammer, remove and discard the input shaft seal.

6. Using a center punch, mark a location in the center of the countershaft bolt cover. Using a drill bit of the appropriate size for the dent puller, drill a hole in the center of the countershaft bolt cover. Drill the hole to pierce the countershaft bolt cover approximately 2 mm (0.078 in) in depth.

7. Using the Slide Hammer and a dent puller, remove the countershaft bolt cover.

8. Install the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool. Position the shift shaft into 4th gear.

9. With the help of an assistant, hold the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool and remove the countershaft bolt.

10. Using the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool, hold the output shaft flange and remove the output shaft flange bolt.

11. Using the 2 or 3 Jaw Puller and the Step Plate, remove the output shaft flange.

12. Remove the output shaft seal.

13. Remove the OSS sensor bolt and the OSS sensor.

14. Remove the reverse lamp switch.
    1. Detach the electrical connector retainer.
    2. Remove the reverse lamp switch.

15. Remove the LH and RH reverse gear shift fork pivot bolts.

16. Using the Detent Remover and the Slide Hammer, remove the 4 shift rail detents.

17. Remove the 15 transmission case bolts.

18. Using the 2 Jaw Puller and the Step Plate, remove the rear transmission case.

19. NOTE: To remove the reverse shift fork and the reverse shift rail assembly, the transmission must be in neutral and the groves on the shift rails must be aligned with the interlock plate.

    Remove the reverse shift fork and the reverse shift rail assembly.
    • Inspect the reverse shift fork and the reverse shift rail assembly for wear or damage. Install new components as necessary.

20. Using the Detent Remover and the Slide Hammer, remove the shift shaft stop pin.

21. Remove the shift shaft.

22. Using the Push/Puller Set, Step Plate and the Synchro Gear Pack Remover, remove the 1st gear, the reverse gear and the reverse gear synchronizer assembly.
    • Inspect the 1st and reverse gears for wear or damage. Install new gears as necessary.
    • Inspect the reverse gear needle bearing and the reverse gear needle bearing race for wear or damage. Install new components as necessary.
    • Inspect the reverse gear synchronizer assembly and the reverse gear synchronizer ring for wear or damage. Install new components as necessary.

23. Remove the 1st gear needle bearing.
    • Inspect the 1st gear needle bearing for wear or damage. Install a new 1st gear needle bearing as necessary.

24. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st gear synchronizer ring assembly.
    • Inspect all synchronizer ring components for wear or damage. Install new components as necessary.

25. NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.

    Remove the 3 pressure pieces.

26. NOTE: Index-mark the synchronizer sleeve to the synchronizer hub before removal.

    Remove the 1st/2nd shift fork, the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.
    • Inspect the 1st/2nd shift fork and the 1st/2nd shift rail for wear or damage. Install new components as necessary.
    • Inspect the 1st/2nd synchronizer sleeve for wear or damage. Install a new 1st/2nd synchronizer assembly as necessary.

27. Remove the magnet.

28. Remove the 2 bolts, spacers, spring and the interlock plate.

29. Remove the 3 center support bolts.

30. Remove the 1st/2nd synchronizer hub snap ring.

31. NOTICE: The center support must be pulled up evenly or damage to the center support or transmission case can occur.

    Using the Push/Puller Set, Step Plate and the Synchro Gear Pack Remover under the center support pull off the center support, 2nd gear and the 1st/2nd synchronizer hub.

32. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st/2nd synchronizer hub, the 2nd gear synchronizer ring assembly and the 2nd gear.
    • Inspect all the components for wear or damage. Install new components as necessary.

33. Remove the 2nd gear needle bearing.
    • Inspect the 2nd gear needle bearing for wear or damage. Install a new needle bearing as necessary.

34. Remove the center support.
    • Inspect the center support for wear or damage. Install a new center support as necessary.

35. NOTICE: When removing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

    Unlock the bearing cage tabs and slightly expand the bearing cages. Remove the center support bearings by sliding them up the shaft assemblies.

36. Remove the 2 LH and the 2 RH shift fork pivot bolts.

37. Remove the 3rd/4th shift rail and the 3rd/4th shift fork.

38. Remove the 5th/6th shift rail and the 5th/6th shift fork.

39.  WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

    NOTICE: Use an assistant when pressing out the countershaft and output shaft, do not allow the shafts to bind during removal.

    NOTICE: The countershaft bolt must be removed prior to pressing out the countershaft or damage to the transmission case will occur.

    With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the Shift Rail Needle Bearing Installer and the Handle, press the countershaft out of the bearing and remove the countershaft and output shaft.

40. Remove the input shaft snap ring.

41.  WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

    NOTICE: Use an assistant when pressing out the input shaft, do not allow the input shaft to drop during removal.

    With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the hydraulic press, remove the input shaft.