Disassembly
MANUAL TRANSMISSION - NSG370DISASSEMBLY
Fig. 8 SHIFT TOWER:
1. Remove shift tower (1) (Fig. 8) bolts (2) and remove tower.
Fig. 9 SHIFT TOWER OPENING:
2. Through shift tower opening (1) (Fig. 9) shift two shift rails (2) forward to engage two gears.
Fig. 10 BACK-UP LAMP SWITCH:
3. Remove back-up lamp switch (1) bolt (2) and remove switch (Fig. 10).
Fig. 11 COUNTERSHAFT PLUG:
4. Remove countershaft plug (1) (Fig. 11) from the front housing (2) with a seal pick.
Fig. 12 COUNTERSHAFT BOLT:
5. Remove countershaft bolt (1) (Fig. 12) from the front housing (2).
Fig. 13 OUTPUT SHAFT SEAL:
6. Remove output shaft (1) (Fig. 13) seal (2) from rear housing (3) with a seal pick.
Fig. 14 OUTPUT SHAFT SNAP RING:
7. Remove output shaft (1) (Fig. 14) snap ring (2) 4x4 only.
8. Stand transmission on the rear housing and remove the housing bolts.
Fig. 15 SPLIT HOUSING:
9. Remove front housing (1) (Fig. 15) from the rear housing (2).
Fig. 16 SHIFT RAIL SUPPORT PLATE:
10. Remove shift rails (1) (Fig. 16) support plate (2) bolts.
Fig. 17 INPUT SHAFT ROLLER BEARING:
11. Remove input shaft (1) (Fig. 17) roller bearing (2).
Fig. 18 FIFTH GEAR BLOCKER RING:
12. Remove fifth gear synchronizer blocker ring (1) (Fig. 18) from 5-6 synchronizer hub (2).
Fig. 19 FIFTH GEAR FRICTION RING:
13. Remove fifth gear synchronizer friction ring (1) (Fig. 19) from 5-6 synchronizer hub (2).
14. Set geartrain and shift rails with rear housing into Build Fixture 9633.
Fig. 20 MAINSHAFT REMOVER:
15. Remove mainshaft shaft (1) (Fig. 20) from rear housing bearing with Remover 9636 (2).
Fig. 21 MAIN/COUNTERSHAFT:
16. Remove mainshaft (1), countershaft (2) and shift rails/forks (3) from fixture (Fig. 21).
MAINSHAFT
1. Place mainshaft with 5-6 synchronizer facing up in build Fixture 9648 and place in a vise.
Fig. 22 5-6 SYNCHRO SLEEVE DETENTS:
2. Push 5-6 synchronizer sleeve (1) (Fig. 22) down on hub and remove detents (2) springs and balls.
Fig. 23 5-6 SYNCHRONIZER SLEEVE:
3. Remove 5-6 synchronizer sleeve (1) (Fig. 23) from hub (2).
Fig. 24 5-6 SYNCHRONIZER HUB SNAP RING:
4. Remove 5-6 synchronizer hub (1) (Fig. 24) snap ring (2).
NOTE: All snap rings are select fit from the factory, and must be installed in their original location.
Fig. 25 5-6 SYNCHRONIZER HUB:
5. Remove 5-6 synchronizer hub (1) (Fig. 25) and sixth gear synchronizer rings (2) with a three jaw puller. Place puller jaws under sixth gear synchronizer rings (2).
Fig. 26 SIXTH GEAR & BEARING:
6. Remove sixth gear (1) (Fig. 26) and bearing (2).
Fig. 27 3-4 GEAR:
7. Third gear (1) (Fig. 27) and fourth gear (2) are serviced with the mainshaft only.
8. Remove mainshaft from Fixture 9648. Turn fixture over in vise and set opposite end of mainshaft in the fixture.
Fig. 28 REVERSE GEAR SYNCHRONIZER SLEEVE:
9. Remove reverse gear (1) (Fig. 28) synchronizer sleeve (2) off synchronizer hub.
Fig. 29 REVERSE SYNCHRONIZER HUB DETENT:
10. Remove reverse synchronizer hub (1) (Fig. 29) detents (2).
Fig. 30 REVERSE SYNCHRONIZER HUB:
11. Remove reverse synchronizer hub (1) (Fig. 30) with three jaw puller (2). Place puller jaws in hub detent openings.
Fig. 31 REVERSE SYNCHRONIZER:
12. Remove reverse gear (1) (Fig. 31) synchronizer ring (2).
Fig. 32 REVERSE GEAR:
13. Remove reverse gear (1) (Fig. 32) and bearing (2).
Fig. 33 FIRST GEAR:
14. Remove reverse gear bearing race (1) (Fig. 33), thrust washer (2) and first gear (3) with puller (4). Place puller jaws under first gear (3).
15. Remove first gear bearing.
16. Remove first gear synchronizer rings.
Fig. 34 1-2 SYNCHRONIZER DETENT:
17. Push 1-2 synchronizer sleeve down on hub. Remove 1-2 synchronizer hub (1) (Fig. 34) detents (2), balls and springs.
Fig. 35 1-2 SYNCHRONIZER SLEEVE:
18. Remove 1-2 synchronizer sleeve (1) (Fig. 35) from synchronizer hub (2).
Fig. 36 1-2 SYNCHRONIZER HUB SNAP RING:
19. Remove 1-2 synchronizer hub (1) (Fig. 36) snap ring (2).
NOTE: All snap rings are select fit from the factory, and must be installed in their original location.
Fig. 37 SECOND GEAR:
20. Remove 1-2 synchronizer hub (1) (Fig. 37), synchronizer rings and second gear (2) off shaft with a press. Place second gear (2) on press plates and press shaft through 1-2 synchronizer hub (1), synchronizer rings and second gear (2)
Fig. 38 COUNTERSHAFT:
The countershaft (1) and 3-4 synchronizer (2) are serviced as an assembly only (Fig. 38).
FRONT HOUSING
Fig. 39 INPUT SHAFT RETAINER:
1. Remove input shaft retainer (1) (Fig. 39) bolts (2) and remove retainer.
Fig. 40 COUNTERSHAFT BEARING RETAINER:
2. Remove countershaft bearing (1) (Fig. 40) retainer (2) bolts and remove retainers.
Fig. 41 COUNTERSHAFT BEARING FRONT HOUSING:
3. Remove countershaft bearing (1) (Fig. 41) from housing (2) with a hammer and driver.
Fig. 42 INPUT SHAFT BEARING RETAINER:
4. Remove input shaft (1) (Fig. 42) bearing retainer (2, 3) bolts and remove retainers.
5. Remove input shaft and bearing from housing with a dead blow hammer.
Fig. 43 INPUT SHAFT SEAL:
6. Remove input shaft seal (1) (Fig. 43) from housing (2) with a hammer and driver.
INPUT SHAFT
Fig. 44 INPUT SHAFT BEARING SNAP RING:
1. Remove input shaft bearing (1) (Fig. 44) snap ring (2).
NOTE: All snap rings are select fit from the factory, and must be installed in their original location.
Fig. 45 INPUT SHAFT BEARING REMOVAL:
2. Remove input shaft bearing (1) (Fig. 45) with Splitter 1130 (2) and press. Place splitter around bearing retainer lip.
REAR HOUSING
Fig. 46 IDLER SHAFT BOLT:
1. Remove reverse idler gear shaft bolt (1) (Fig. 46) from housing (2).
Fig. 47 PULL IDLER SHAFT:
2. Thread idler gear shaft bolt (1) (Fig. 47) into the shaft (2). Then work shaft (2) out of the idler gear.
Fig. 48 IDLER SHAFT SUPPORT:
3. Remove reverse idler gear (1) (Fig. 48) shaft support (2).
Fig. 49 IDLER GEAR THRUST WASHER:
4. Remove reverse idler gear (1) (Fig. 49) thrust washer (2).
Fig. 50 IDLER GEAR BEARING:
5. Remove reverse idler gear (1) (Fig. 50) and bearing (2).
Fig. 51 BEARING CAGE:
6. Break plastic countershaft roller bearing cage (1) (Fig. 51) with a screw driver (2). Then remove cage and roller bearing.
Fig. 52 BEARING SHELL PULLER:
7. Remove countershaft roller bearing shell (1) (Fig. 52) from the rear housing with Remover 7794-A (2) and Slide Hammer C-637.
Fig. 53 REAR MAINSHAFT BEARING RETAINER:
8. Remove mainshaft bearing (1) (Fig. 53) retainer (2) bolts and remove retainers.
9. Remove bearing from housing with a hammer and driver.