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MANUAL TRANSMISSION
21 - 37
A w o r n p i l o t b u s h i n g w i l l cause noise a n d i n p u t
shaft m i s a l i g n m e n t . T h e result is h a r d s h i f t i n g a n d
noise.
A w o r n or damaged clutch disc, pressure plate, or
release bearing can cause h a r d s h i f t i n g a n d gear
clash.
Damaged or w o r n c l u t c h hydraulic components, or
leaks i n t h e fluid lines or cylinders w i l l cause h a r d
s h i f t i n g a n d gear clash. F a i l u r e of one o f t h e clutch
hydraulic cylinders can result i n incomplete clutch
release or engagement.
Be sure t h a t t h e c l u t c h components are a l l i n good
condition before removing t h e transmission for re-
pair.
TRANSMISSION REMOVAL
(1) Remove t h e shift lever retainer b y pressing
down, r o t a t i n g t h e retainer counterclockwise s l i g h t l y
and releasing i t (Fig. 2).
(2) Remove transfer case ( i f so equipped) as follows:
(3) Remove 4 bolts attaching s k i d plate rear cross-
member t o underside o f frame, i f so equipped.
(4) Remove bolts attaching front end o f s k i d plate
to transmission crossmember. Remove s k i d plate.
(5) Disconnect speedometer cable.
(6) Disconnect front and rear output shafts (support
each shaft, do n o t allow shafts to hang).
(7) Disconnect shift rods a t transfer case.
(8) W i t h suitable jack, support transfer case. Be
sure transfer case is safely secured i n removing de-
vice.
(9) Remove extension to transfer case m o u n t i n g
bolts.
(10) Move transfer case rearward t o disengage
front i n p u t spline.
(11) Lower transfer case assembly and remove from
under vehicle.
(12) Disconnect back-up lamp switch lead.
(13) I n s t a l l engine support f i x t u r e C-3487A, w i t h
adapter tool DD-1279 f i r m l y over frame r a i l s . Be
sure support ends are u p against underside o f o i l p a n
flange.
(14) Support transmission w i t h a suitable jack.
(15) Remove transmission crossmember.
(16) Remove transmission to clutch housing bolts.
Slide transmission t o w a r d rear u n t i l drive p i n i o n
shaft clears clutch disc, before lowering transmission.
(17) Lower transmission and remove from under
vehicle. Thoroughly clean exterior of u n i t .
TRANSMISSION DISASSEMBLY
SHIFT COVER AND PARKING
BRAKE
(1) M o u n t transmission i n holding f i x t u r e .
(2) Shift gears i n t o n e u t r a l by replacing gear shift
lever temporarily, or using bar or screwdriver.
RETAINER
BOOT
Fig. 2 NP435 Gear Shift Lever Components
(3) Remove cover screws. Second screw f r o m front
on each side is shouldered w i t h s p l i t washer for i n -
s t a l l a t i o n alignment.
(4) W h i l e l i f t i n g cover, rotate s l i g h t l y counterclock-
wise t o provide clearance to shift forks a n d remove
cover (Fig. 3).
(5) Remove extension housing.
Fig. 3 Transmission Cover Assembly
SYNCHRONIZER
END PLAY
CHECK
Measure end play between synchronizer outer stop
r i n g a n d t h i r d speed gear (Fig. 4). Do t h i s before re-
m o v i n g d r i v e p i n i o n and mainshaft. Use t w o feeler
gauges as shown.
Correct end play is 1.27 to 1.78 m m (.050 t o .070
inch). Record end play so t h a t correction shims can
be i n s t a l l e d d u r i n g reassembly. T h i c k or t h i n shims
are available as required.
DRIVE
PINION
(1) Remove drive pinion bearing retainer.
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