Rear Cover Removal

Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the rear cover, replace the following:
- O-rings
- Mainshaft and countershaft locknuts
- Conical spring washers
- Rear cover gasket
- 24 mm washers

1. Remove the one bolt securing the ATF cooler lines to the transmission housing and the line bolts, then remove the ATF cooler lines.
2. Remove the 34 x 1.5 mm sealing bolt from the rear cover and the ten bolts securing the rear cover.





3. Using snap ring pliers, expand the snap ring on the countershaft ball bearing and remove the rear cover.
4. Remove the two ATF feed pipes from the transmission housing.





5. Slip the special tool onto the mainshaft.
6. Engage the park pawl with the park gear.





7. Cut the lock tabs of each shaft locknut using a chisel as shown, then remove the locknuts from each shaft.

CAUTION: Keep all of the chiseled particles out of the transmission.

NOTE: Countershaft locknut has left-hand threads. Always wear safety glasses.

8. Remove the special tool from the mainshaft after removing the locknuts.
9. Remove the 24 mm washer, ball bearing, reverse gear, reverse gear distance collar, and conical spring washer from the mainshaft.
10. Remove the 24 mm washer, ball bearing, 25 mm thrust washer, thrust needle bearing, reverse gear, thrust needle bearing, needle bearing, reverse gear collar, reverse clutch assembly, conical spring washer, and reverse clutch distance collar from the countershaft.
11. Remove the 2nd clutch assembly from the main shaft.
12. Remove the park gear from the countershaft, and the 29 mm thrust washer, thrust needle bearing, and 2nd gear from the mainshaft together.
13. Remove the thrust needle bearing, 45.5 x 60 mm thrust washer, needle bearings, 2nd gear one-way clutch, and 2nd gear assembly from the countershaft.
14. Remove the needle bearing, thrust needle bearing,and 2nd gear collar from the mainshaft.
15. Disconnect the connectors from the transmission sub-harness.