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MANUAL TRANSMISSION
Fig. 11 Removing/Installing
1-2 Clutch
Gear And
Snap
Ring
semble components p a r t s u n l e s s i n s p e c t i o n i n d i -
cates replacement p a r t i s r e q u i r e d .
DRIVE
PINION/COUNTERSHAFT
GEAR
DISASSEMBLY
(1) Remove snap r i n g t h a t r e t a i n s d r i v e p i n i o n
bearing to p i n i o n shaft.
(2) Remove p i n i o n bearing w i t h shop press a n d
press plates or bearing remover tool.
(3) Remove pilot bearing snap r i n g a n d remove 16
bearing rollers from bore i n d r i v e p i n i o n .
(4) Remove countershaft gear a n d t h r u s t washers
f r o m bottom of case.
(5) Remove arbor tool from countershaft gear. T h e n
remove needle bearings, t h r u s t washers a n d spacers
from gear. Total o f 76 needle bearings are used.
REVERSE
GEAR/SHAFT/LEVER/FORK
REMOVAL
The reverse idler gear shaft is a n extremely t i g h t
f i t i n the case. To avoid damaging t h e shaft or t h e
case, remove t h e shaft only as described i n t h e fol-
l o w i n g procedure. Power steering wormshaft seal re-
mover tool C-3638 and a 7/16 socket are r e q u i r e d for
shaft removal.
(1) Remove backup lamp switch.
(2) Place 7/16 socket (1/4 or 3/8 i n c h drive) o n end
of power steering wormshaft seal remover tool C-
3638 (Fig.-12).
(3) Position tool i n case w i t h 7/16 socket against
end of shaft and opposite e n d o f tool against case
(Fig. 12).
(4) T u r n screw of tool of tool C-3638 t o press shaft
out o f case. I f shaft does n o t come a l l t h e w a y o u t of
case, use a 7/16 deep socket and/or a 3 i n c h extension
to press shaft completely o u t o f case.
(5) Remove reverse idler gear f r o m case a n d re-
move woodruff key from idler gear shaft.
(6) Following steps need only be performed i f o i l
leakage around reverse lever shaft was noted (Fig.
12).
•
REMOVED
LEVER
RH93
Fig. 12 Removing
Reverse
Idler Gear
Shaft
(7) Remove a n y b u r r s from reverse lever shaft to
avoid d a m a g i n g eases bore.
(8) Carefully push reverse lever shaft i n w a r d and
remove i t f r o m case.
(9) Remove shaft seal a n d seal retainer from case
bore.
CLEANING AND INSPECTION
Clean t h e transmission case thoroughly w i t h sol-
vent. D r y t h e case and gears w i t h compressed a i r b u t
d o n o t use compressed a i r o n a n y o f t h e bearings.
A l l o w t h e bearings t o a i r d r y o r wipe t h e m d r y w i t h
clean shop towels.
The magnetic disc a t t h e b o t t o m of the case can be
removed for cleaning by p r y i n g off t h e magnet re-
t a i n i n g clip. A f t e r cleaning t h e magnetic disc w i t h a
clean cloth, t h e disc and r e t a i n i n g clip can be r e i n -
stalled b y pressing t h e clip onto t h e r i b i n t h e case.
Transmission Case
Inspect the case for cracks, stripped bolt threads, or
damaged gasket m a t i n g surfaces. Check t h e gasket
and machined surfaces for severe scoring, cracks,
nicks, or a n y condition t h a t w o u l d render t h e case
u n f i t for f u r t h e r service. T h e front m a t i n g surface
should be smooth. M i n o r scratches, burrs or nicks
can be reduced w i t h sandaper or a fine tooth m i l l
file. I f any bolt threads are stripped, i n s t a l l Helicoil,
or equivalent, t h r e a d inserts.
Mainshaft
Inspect t h e mainshaft gear a n d bearing
surfaces
(Fig. 13). Check for signs o f wear, scoring, or any
condition t h a t w o u l d not allow t h e shaft to be reused.
Be sure t h e snap r i n g grooves i n the shaft are i n
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