Tools Required

1. Remove the two bolts which attach the idler shaft segment and the idler shaft support collar to the rear housing.



2. Remove the backup lamp switch from the rear housing.
3. Remove the bolt and the electronic speed sensor from the rear housing.
4. Remove the shift shaft block-out bushing pin from the front housing.



5. Use the J 36509 and the J 23907 in order to remove the following components from the front housing:

•	The detent plug

•	The spring

•	The plunger

6. Slide the hammer with the 6 mm end into the hole in the front housing.



7. Remove the five bolts which secure the input shaft bearing retainer to the front housing.
8. Use the J 23907 to remove the input shaft bearing retainer from the front housing.
9. Remove the snap ring.



10. Remove the nine bolts which attach the front housing to the rear housing.
11. Angle the front housing up and press down on the rear housing in order to separate the front housing from the rear housing.
12. Remove the countershaft roller bearing from the countershaft or the bearing shell.



13. Remove the shift shaft lever roll pin from the shift shaft lever:

•	Rotate the shift shaft lever and the shift shaft bushing.

Important: Do not lose the shift shaft lever plunger or the spring when removing the shift shaft lever roll pin from the rear housing.

•	Remove the shift shaft lever plunger and the spring.

•	Support the shift shaft end while driving out the shift shaft lever roll pin.

•	Allow the roll pin to clear the second gear during removal.

Notice: Do not use excessive force when removing the shift shaft. Excessive force will "peen" the shift shaft and damage the rear housing shift shaft bearing causing increased shift effort.

Important: 

•	Do not bend the shift rail when removing the roll pin.

•	Use an air gun with a 5 mm (3/16 inch) drift punch in order to remove the roll pin.

•	The roll pin will fall into the rear housing.

14. Remove the shift shaft socket roll pin from the bottom of the shift shaft socket.




Notice: Do not use excessive force when removing the shift shaft. Excessive force will "peen" the shift shaft and damage the rear housing shift shaft bearing causing increased shift effort.

15. Remove the following components:

•	The shift shaft

•	The shift shaft socket

•

The lever

•	The shift shaft block-out bushing

16. Rotate the third-fourth shift fork counterclockwise.

Remove the third-fourth shift fork.




17. Remove the five bolts which secure the output shaft bearing retainer to the center of the rear housing.
18. Remove the rear housing from the gear assemblies.
19. Remove the reverse idler gear assembly.
20. Remove the output shaft bearing retainer.
21. Remove the shift forks.
22. Remove the countershaft.
23. Remove the countershaft bearing snap ring.
24. Remove the countershaft bearing.

The countershaft bearing must be pressed off the counter shaft.

25. Remove the fifth counter gear from the counter shaft.



26. Use the J 21427-A and the J 8105 to remove the speed sensor rotor from the output shaft.

Discard the speed sensor rotor.

27. Remove the snap ring from the output shaft.
28. Use the J 21427-A and the J 8105 to remove the output shaft bearing from the output shaft.



29. Remove the fifth speed gear from the output shaft.
30. Remove the snap ring from the output shaft.
31. Remove the following components from the output shaft:

•	The synchronizer blocking ring

•	The synchronizer and the hub

•	The synchronizer blocking ring

•	The reverse speed gear assembly




32. Leave the synchronizer rings on the fifth-reverse synchronizer assembly in order to prevent the synchronizer detent balls from popping out.



33. Remove the input shaft and the pocket bearing from the output shaft.



34. Remove the snap ring.
35. Use a hydraulic press in order to remove the following components from the main shaft:

•	The third-fourth synchronizer assembly

•	The synchronizer blocking rings

•	The third speed gear




36. Remove the following components from the main shaft:

•	The retaining ring

•

The pin

•	The two thrust washer halves




37. Remove the second gear from the main shaft.
38. Remove the following components from the main shaft:

•	The inner cone

•	The middle cone

•	The synchronizer ring




39. Remove the snap ring.

Important: Scribe the synchronizer hub to the output shaft prior to disassembly.

40. Use the J 22912-01 and a hydraulic press to remove the following components:

•	The synchronizer

•	The synchronizer ring

•	The inner cone

•	The middle cone

•	The first gear




41. Leave the synchronizer rings on the first-second synchronizer assembly in order to prevent the synchronizer detent balls from popping out.



42. Remove the following components from the reverse idler shaft:

•	The segment

•

The gear

•	The bearing assembly

•	The collar

•	The two O-rings from the shaft

Tools Required

1. Remove the two bolts which attach the idler shaft segment and the idler shaft support collar to the rear housing.



2. Remove the backup lamp switch from the rear housing.
3. Remove the bolt and the electronic speed sensor from the rear housing.
4. Remove the shift shaft block-out bushing pin from the front housing.



5. Use the J 36509 and the J 23907 in order to remove the following components from the front housing:

•	The detent plug

•	The spring

•	The plunger

6. Slide the hammer with the 6 mm end into the hole in the front housing.



7. Remove the five bolts which secure the input shaft bearing retainer to the front housing.
8. Use the J 23907 to remove the input shaft bearing retainer from the front housing.
9. Remove the snap ring.



10. Remove the nine bolts which attach the front housing to the rear housing.
11. Angle the front housing up and press down on the rear housing in order to separate the front housing from the rear housing.
12. Remove the countershaft roller bearing from the countershaft or the bearing shell.



13. Remove the shift shaft lever roll pin from the shift shaft lever:

•	Rotate the shift shaft lever and the shift shaft bushing.

Important: Do not lose the shift shaft lever plunger or the spring when removing the shift shaft lever roll pin from the rear housing.

•	Remove the shift shaft lever plunger and the spring.

•	Support the shift shaft end while driving out the shift shaft lever roll pin.

•	Allow the roll pin to clear the second gear during removal.

Important: 

•	Do not bend the shift rail when removing the roll pin.

•	Use an air gun with a 5 mm (3/16 inch) drift punch in order to remove the roll pin.

•	The roll pin will fall into the rear housing.

14. Remove the shift shaft socket roll pin from the bottom of the shift shaft socket.



15. Remove the following components:

•	The shift shaft

•	The shift shaft socket

•

The lever

•	The shift shaft block-out bushing

16. Rotate the third-fourth shift fork counterclockwise.

Remove the third-fourth shift fork.




17. Remove the five bolts which secure the output shaft bearing retainer to the center of the rear housing.
18. Remove the rear housing from the gear assemblies.
19. Remove the reverse idler gear assembly.
20. Remove the output shaft bearing retainer.
21. Remove the shift forks.
22. Remove the countershaft.
23. Remove the countershaft bearing snap ring.
24. Remove the countershaft bearing.

The countershaft bearing must be pressed off the counter shaft.

25. Remove the fifth counter gear from the counter shaft.



26. Use the J 21427-A and the J 8105 to remove the speed sensor rotor from the output shaft.

Discard the speed sensor rotor.

27. Remove the snap ring from the output shaft.
28. Use the J 21427-A and the J 8105 to remove the output shaft bearing from the output shaft.



29. Remove the fifth speed gear from the output shaft.
30. Remove the snap ring from the output shaft.
31. Remove the following components from the output shaft:

•	The synchronizer blocking ring

•	The synchronizer and the hub

•	The synchronizer blocking ring

•	The reverse speed gear assembly




32. Leave the synchronizer rings on the fifth-reverse synchronizer assembly in order to prevent the synchronizer detent balls from popping out.



33. Remove the input shaft and the pocket bearing from the output shaft.



34. Remove the snap ring.
35. Use a hydraulic press in order to remove the following components from the main shaft:

•	The third-fourth synchronizer assembly

•	The synchronizer blocking rings

•	The third speed gear




36. Remove the following components from the main shaft:

•	The retaining ring

•

The pin

•	The two thrust washer halves




37. Remove the second gear from the main shaft.
38. Remove the following components from the main shaft:

•	The inner cone

•	The middle cone

•	The synchronizer ring




39. Remove the snap ring.

Important: Scribe the synchronizer hub to the output shaft prior to disassembly.

40. Use the J 22912-01 and a hydraulic press to remove the following components:

•	The synchronizer

•	The synchronizer ring

•	The inner cone

•	The middle cone

•	The first gear




41. Leave the synchronizer rings on the first-second synchronizer assembly in order to prevent the synchronizer detent balls from popping out.



42. Remove the following components from the reverse idler shaft:

•	The segment

•

The gear

•	The bearing assembly

•	The collar

•	The two O-rings from the shaft