Disassembly

Disassembly
1. Set the transmission on a work bench.





2. Remove the case cover bolts (1) and case cover (2).





3. Use Seal Remover SST 307-048 (T47P-77248-A) or equivalent to remove the extension housing sea].
4. Remove the extension housing bolts and extension housing.





5. Slide the first/second and third/fourth synchronizer sleeves forward to lock the transmission into first and third gears.





6. Remove and discard the countershaft locknut.





7. Remove the (A) countershaft rear bearing and (B) countershaft rear bearing thrust washer.





8. Use SST 49 UN01 011 to remove and discard the secondary shaft rear bearing lock nut.





9. Remove the reverse idler shaft bolt.





10. Remove the reverse idler gear and bushing.





11. Use Puller Set Bearing SST 49 0839 425C to remove the secondary shaft rear bearing.

Caution:
- Ensure all tools are properly positioned to avoid damaging the parts being removed.





12. Remove the secondary shaft reverse gear (A) and bushing (B).





13. Remove the spacer or sleeve.





14. Remove the countershaft reverse gear (A), two countershaft reverse gear bearings (B), and reverse synchronizer blocking ring (C).





15. Remove the countershaft split washer.





16. Remove the bolt.





17. Remove the fifth/reverse synchronizer (A), gear shifter fork (B), and reverse gear shift rail (C) as an assembly.





18. Remove the countershaft fifth gear synchronizer blocking ring.





19. Remove the fifth and reverse shift lever snap ring (A) and fifth and reverse shift lever (B).





20. Remove the bolt and slide the shaft out of the case.





21. Remove the countershaft fifth speed gear.





22. Remove the countershaft fifth speed gear split bearing (A) and race (B).





23. Remove the secondary shaft fifth speed gear.





24. Remove the (1) rear bearing retainer bolts and (2) rear bearing retainer.





25. Remove the front bearing cover bolts.





26. Remove the front bearing cover.
1) Install Front Bearing Cover Removing Bolt Set SST 308-171 (T88T-7025-D) or M8 X 1.25 (40 mm or longer) bolts into the slave cylinder bolt locations.
2) Remove the front bearing cover.
3) Alternately tighten the bolts until the front bearing cover can be removed by hand.





27. Remove the fluid baffle (A), fluid baffle shim (B), and countershaft bearing shim (C).





28. Remove the bolt.





29. Remove the oil trough.





30. Remove the primary shaft bearing outer race.





31. Remove the secondary shaft center bearing race.





32. Separate the primary shaft (A) and secondary shaft (B).





33. Remove the secondary shaft.





34. Remove the primary shaft.





35. Remove the countershaft cluster gear.
36. Inspect the countershaft cluster gear for damage.