Disassembly

1. Install suitable bolts and washers in intermediate plate. Then clamp plate and gear assembly in vise. Use enough washers to prevent bolts from touching. Also be sure vise jaws are clamped on bolt heads.





2. Remove countershaft fifth gear retaining snap-ring.





3. Remove bolt holding fifth gear shift fork to shift rail.





4. Remove fifth gear blocker ring from countershaft assembly with Puller L-4407.





5. Remove fifth gear synchro ring.





6. Remove the countershaft fifth gear assembly from countershaft.





7. Remove fifth gear thrust ring from countershaft.





8. Remove fifth gear thrust ring lock ball from countershaft.

NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission. Whenever a pin or ball is removed, it should be identified in such a way that it can be reinstalled in the same location from which it was removed.

9. Remove bolt holding reverse idler gear shaft lock plate to the intermediate plate.





10. Remove reverse idler gear shaft and reverse idler gear.





11. Remove bolts holding output shaft rear bearing retainer to the intermediate plate and remove retainer.





12. Remove bolts holding 1-2 and 3-4 shift forks to the shift rails and discard bolts.





13. Remove bolts holding reverse shift arm bracket to intermediate plate.





14. Remove snap-ring holding output shaft rear bearing into the intermediate plate.
15. Remove countershaft rear bearing snap-ring.





16. With aid of an assistant, support the mainshaft and countershaft. Tap on the rear of the mainshaft and countershaft with a suitable plastic mallet. This will release the countershaft from the countershaft rear bearing and the mainshaft rear bearing from the intermediate plate. The countershaft will release from the countershaft bearing first and can be removed by moving the countershaft rearward and downward.





17. Remove the mainshaft by moving the mainshaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks.





18. Remove the 3-4 shift fork from the 3-4 shift rail.
19. Remove the snap-ring from near the end of the 1-2 shift rail to allow the removal of the 1-2 shift fork.





20. Remove the 1-2 shift fork from the 1-2 and the 3-4 shift rails.





21. Remove threaded plugs from intermediate plate. Then remove lock ball and spring from plug holes with pencil magnet. Note that the bottom spring is shorter in length than the other two springs.
22. Remove the intermediate plate from the vise, rotate the plate 180�, and reinstall the plate in the vise using the same bolt and washer mounting setup.

CAUTION: The interlock balls and pins are different sizes and shapes. Be sure to correctly identify which position an item is removed from to ensure that it is reinstalled in the same location.





23. Remove fifth gear shift rail.





24. Remove fifth gear check ball and interlock pin.





25. Remove reverse shift head and rail assembly.
26. Remove snap-ring holding 4th gear/reverse shift rail into intermediate plate.





27. Remove 4th/reverse shift rail and reverse shift fork and arm assembly from intermediate plate.





28. Remove interlock pin from 4th/reverse shift rail.





29. Remove 4th/reverse elongated check ball.
30. Remove snap-ring on 3-4 shift rail.
31. Remove 1-2 shift rail from intermediate plate.





32. Remove interlock pin from 1-2 shift rail.





33. Remove 1-2 shift rail elongated check ball from intermediate plate.
34. Remove 3-4 shift rail from intermediate plate.