Tools Required

J 8433 Two Jaw Puller

1. Remove the drain plug (3) and drain the transmission fluid and discard washer.

Discard the washer.




2. Remove the backup lamp switch (2) and washer (1) from the case.

Discard the washer.




3. Remove the output sensor (1) and bolt (2) from the rear extension housing.



4. Using a suitable tool, release the staking of the propshaft flange nut (3).
5. Remove the thrust washer (2) from the propshaft flange assembly.
6. Remove the propshaft flange nut (3) and propshaft flange assembly (1).

Notice: Refer to General Repair Instructions in the Preface section.




7. To release the staking, insert a suitable tool into the gap between the select shift lever retainer (2) and the rod.
8. Using a suitable tool, rotate the select shift lever retainer (2) forward.
9. Using a suitable tool, remove the shift lever pin (1).



10. Remove the shift lever rod universal joint (1), damper (2) and select shift lever retainer (3) from the end of the shift selector.



11. Remove the transmission housing to extension housing retaining bolts (1).
12. Remove the extension housing (2) from the transmission..



13. Remove the rear output shaft rear bearing spacer (1) from the main shaft.
14. Remove the vehicle speed sensor drive gear (2) from the main shaft.
15. Remove the locking ball (3) from the main shaft.
16. Remove the main shaft bearing oil slinger (4) from the main shaft.



17. Remove the transmission case to clutch housing inner retaining bolts (1).
18. Remove the transmission case to clutch housing outer retaining bolts (2).



19. Remove the clutch housing hole plug (1) from the clutch housing.



20. Remove the following components from the rear case housing:

•	the shift shaft detent plug (3)

•	the shift shaft detent spring (2)

•	the shift shaft detent pin (1)




21. Remove the intermediate case to rear case housing retaining bolts (1).

Notice: Refer to Machined Surface Damage Notice in the Preface section.

22. Using a suitable tool, separate the rear case housing from the intermediate case housing.
23. Remove the rear case housing.



24. Remove the oil trough to intermediate case housing retaining bolts (1).
25. Remove the oil trough (2) from the intermediate case housing.



26. Remove the oil trough pipe (1) from the intermediate case.
27. Remove the reverse idler gear shaft to intermediate case retaining bolt (2).
28. Remove the reverse idler gear shaft washer (3) from the retaining bolt and discard.

Discard the washer.

Notice: Refer to Machined Surface Damage Notice in the Preface section.




29. Using a suitable tool, separate the intermediate case (1) from the front clutch housing (2).
30. Remove the intermediate case housing (1) from the clutch housing.



31. Remove the shift shaft selector lever (1) from the clutch housing (2).



32. Remove the rear output shaft (1), input shaft bearing (2) and blocking ring (3) from the 6th gear synchronizer assembly.



33. Remove the reverse idler gear bearing (3), reverse idler gear (2) and the reverse idler gear shaft (1).



34. Remove the shift counter lever bracket (2) to clutch housing retaining bolts (1).



35. Remove the front counter shaft bearing to clutch housing snap ring (1).



36. Using a suitable tool, tap on transmission front case (1) in order to disengage the countershaft bearing's snap ring.



37. Remove the rear input shaft bearing to clutch housing snap ring (1).



38. Hold the countershaft. Using a suitable tool tap on the transmission front case (1) in order to disengage the snap ring. Separate the input shaft and countershaft from clutch housing.



39. Remove the input shaft (1), countershaft and shift rails as an assembly from the clutch housing (2).



40. Separate the shift rails (1), the input shaft (2) and countershaft (3).