Transmission

Disassembly

1. Mount transmission (7003) in Bench Mounted Holding Fixture T57L-500-B.
   
   
   
   

2. Using a 3/8-inch drive ratchet and extension, remove drain plug located on lower RH side of transmission case (7005) .
   
   
   
   

3. Using a 13mm socket, position shift control selector lever and housing (7210) in NEUTRAL position and remove turret cover retaining bolts.
   
   
   
   

4. Using a suitable pry bar, break turret cover-to-extension housing seal by prying carefully between extension housing (7A039) and cover. Remove turret cover.
   
   
   
   

    CAUTION: Do not attempt to remove the gearshift offset lever (7F018) while the extension housing is bolted in place. A lug, located on the bottom of the gearshift offset lever , meshes with the detent plate preventing enough rearward movement of the gearshift offset lever to allow removal.

5. Using a suitable pin punch and hammer, remove roll pin retaining gearshift offset lever to shifter shaft. Remove gearshift shaft bushing (7K453) .
   
   
   
   

6. Using a 15mm socket, remove extension housing retaining bolts.
   
   
   
   

7. Using a suitable pry bar, break extension housing-to-case seal by prying carefully between extension housing and case .
   
   
   
   

8. Remove extension housing and gearshift offset lever as an assembly by sliding rearward away from case .
   
   
   
   

9. Remove gearshift offset lever , roll pin, shifter interlock spring (7234) and detent ball from extension housing detent plate.
   
   
   
   

10. Using a 10mm socket, remove case cover retaining bolts.
    
    
    
    

11. Using a suitable pry bar, break case cover-to-case seal by prying carefully between case cover (7222) and case .
    
    
    
    

12. To remove case cover , lift it slightly and slide to filler plug side of transmission . When shift mechanism clears groove in reverse gearshift lever (7K002) , continue lifting case cover .
    
    
    
    

13. Support reverse gear shift rail (7240) assembly with a block of wood and drive out roll pin from fifth gear gear shifter fork (7230) with a suitable pin punch.
    
    
    
    

14. Using snap ring pliers, remove fifth gear synchronizer snap ring (7064), retainer, brake ring and synchronizer blocking ring (7107) from rear of countershaft cluster gear (7113) .
    
    
    
    

15. Remove fifth speed cluster gear (7144) , synchronizer (7124) and gear shifter fork as an assembly.
    
    
    
    

16. Using long needlenose pliers, remove reverse idler gear retaining ring (7156) retaining reverse gearshift lever to shift rail rear pin (7K024) .
    
    
    
    

17. Remove shift rail rear pin with Torx® bit driver. Do not remove the reverse gearshift lever at this point.

18. Using a 22mm wrench, remove the backup lamp switch (15520) .
    
    
    
    

19. Rotate reverse gear shift rail clockwise to disengage ball stud from reverse gearshift lever . Pull reverse gear shift rail rearward slightly and rotate reverse gear shift rail counterclockwise to align ball stud with slot in case and remove reverse gear shift rail .
    
    
    
    

20. Press downward on speedometer drive gear retaining clip (17B336) and slide speedometer drive gear (17285) off of output and fifth gear drive shaft (7061) . Remove speedometer drive gear retaining clip .
    
    
    
    

21. Using a 13mm socket, remove main drive gear bearing retainer retaining bolts.
    
    
    
    

22. Using a suitable pry bar, break the main drive gear bearing retainer-to-case seal by prying carefully between main drive gear bearing retainer (7050) and case . Remove main drive gear bearing retainer .
    
    
    
    

23. Rotate input shaft (7017) until flat on fourth gear clutching teeth aligns with countershaft cluster gear . With input shaft properly aligned, remove it from case . Be careful not to drop the 15 countershaft reverse gear bearings (7N270) , spacer or sleeve (7072) or sun gear thrust bearing race (7D235) from rear of input shaft .
    
    
    
    

24. Remove fourth gear synchronizer blocking ring (7107) from the third/fourth synchronizer .
    
    
    
    

    NOTE: If the output shaft rear bearing cup (7169) sticks, it is probably misaligned in the case bore. To free the output shaft rear bearing cup , work the output and fifth gear drive shaft back and forth in the case .

25. Remove output shaft rear bearing cup from rear of case . To partially remove output shaft rear bearing cup , pull rearward on output and fifth gear drive shaft until first gear (1GR) (7100) stops against case .
    
    
    
    

26. Tilt output and fifth gear drive shaft assembly upward and lift out of case .
    
    
    
    

    NOTE: Observe location of reverse gearshift lever , shift fork (7231) and reverse positioning spring prior to removal. Also observe the rotation action of the reverse positioning spring during removal. This will be helpful during assembly.

27. Remove reverse gearshift lever , reverse shift fork and reverse positioning spring from case by grasping reverse gearshift lever and lifting straight up as an assembly.
    
    
    
    

28. Using a suitable pin punch and hammer, remove roll pin from reverse idler gear shaft (7140) .
    
    
    
    

29. Remove reverse idler gear shaft by sliding it out of back of case . Remove reverse idler gear and bushing (7141) and reverse gear overtravel stop (7E397) from case .
    
    
    
    

30. Using a hammer and Locknut Staking Tool T77J-7025-F, flatten tabs on countershaft rear bearing retainer (7195) at all four corners.
    
    
    
    

31. Remove four 13mm bolts from countershaft rear bearing retainer.
    
    
    
    

32. Remove countershaft rear bearing retainer and shim(s).
    
    
    
    

33. Remove rear countershaft bearing race from countershaft cluster gear .

    NOTE: If the race sticks, it is probably misaligned in the case bore. To free the race, work the countershaft cluster gear back and forth in case .

    
    
    
    
    

34. Install Front Hub Remover/Replacer T81P-1104-C1 and Bearing Pulling Attachment D84L-1123-A or equivalent to the countershaft cluster gear with the jaws behind the bearing (7025) , and remove bearing.
    
    
    
    

35. Move countershaft cluster gear rearward through bearing bore. Tilt assembly upward and remove from case .