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6-20
GROUP
6-GENERAL
TRANSMISSION SERVICE
rJ
MAJOR REPAIR OPERATIONS
DJSASSEMBL Y
1.
Mount the transm1ss1on in a
holding fixture and drain the lubri-
cant.
2. Remove the six cap screws that
attach the cover to the case. Remove
the cover and the gasket from the
case.
3.
Remove the six cap screws and
lock washers that attach the extension
housing to the case. Remove the
extension and gasket from the case.
4.
Remove the three cap screws
and lock washers that attach the front
bearing retainer to the case. Remove
the retainer and gasket from the case.
5. Use a soft drift to knock the
countershaft through from the front
to allow the lock plate to be removed.
Remove the lock plate.
(Fig.
10,
page 6-12
).
6. Push countershaft out through
rear of case with dummy counter-
shaft tool No. 7111 C.
(Fig.
11, page
6-12). Lower the countershaft and
dummy shaft to the case bottom.
7. Remove the snap ring that se-
cures the speedometer drive gear on
the
shaft.
Slide the speedometer drive
gear off the output shaft. Remove the
speedometer drive gear drive ball
from the shaft.
8. Pull out input shaft from front
of case. Remove third
speed
blocker
ring.
(Fig.
12,page6-12).
9.
Remove rear
(output
shaft)
bearing outer
snap
ring.
10 .
.
Move second and third
speed
gearshift cam into third gear position.
11. From the underside of the
case, knock out taper pins from each
gearshift camshaft.
(Fig.
13, page
6-12
).
12. Push gearshift cam and shaft
assemblies against the
inside
of the
case.
13. Push the output shaft assem-
bly forward so that the output
shaft
bearing moves through into the gear
case. Move the mainshaft assembly
away from the gearshift forks.
14. Move the first and reverse
sleeve and gear forward into first
speed position (do not move first and
reverse gearshift fork out of neutral
position).
15. Remove first and reverse gear-
shift fork.
16.
Remove second and third
speed gearshift fork.
17. Move the second and third
speed synchro outer sleeve rearwards
into second speed position.
18. Remove output shaft assembly
through top of gear case.
19.
Knock out reverse idler gear
and cluster gear assembly.
20. Remove the synchronizer snap
ring from the front of the output
shaft and slide off the second and
third speed synchronizer assembly
and the second gear with its blocker
ring.
Take note of the synchronizer
assembly hub end positions for
reference in assembly.
21.
Remove the output shaft bear-
ing snap ring and spacer from the
output
shaft
and remove the bearing.
(Fig. 15,page 6-13).
22. Remove the first speed syn-
chronizer and reverse gear assembly
snap ring from the output shaft.
Remove the synchronizer and gear
assembly from the output shaft.
REPLACEMENT
CAM AND SHAFTS AND OIL
SEALS
1.
Using a plastic hammer, drive
the second and third cam and shaft
toward the inside of the case and
separate the detent balls and spring
from !he plunger. Push out the cam
and shaft assemblies, and remove the
plunger.
2.
·
If required, the cam shaft oil
seals or "0" rings may be replaced
by removing them from their grooves
in the cam shafts ("0" rings) or ex-
tracting them from the case (seals).
INPUT SHAFT BEARING
1.
Remove the snap ring and
spacer securing the input shaft bear-
ing, and press the input shaft out of
the bearing and oil slinger.
2. Remove the rollers (14) from
the rear end of the input shaft.
l<'RONT BEARING RETAINER
SEAL
1.
Remove the input shaft seal
from the front bearing retainer as
shown in Fig. 19, page 6·14
2. Install a new input shaft seal
as shown in Fig. 20, page 6-14
SYNCHRONIZERS
1.
Push the synchronizer hub from
each synchronizer sleeve.
2. Separate the inserts and insert
springs from the hubs. Do not
mix
the parts from the second and third
speed synchronizer with the first and
reverse synchronizer (Figs. 39, page
6-21 ).
COUNTERSHAFT GEAR
BEARINGS
1. Remove the dummy shaft, 66
roller bearings, and the 3 bearing
retainer washers from the counter-
shaft gear (Fig. 40).
ASSEMBLY
1.
Use grease to hold 1 ball in rear
of interlock sleeve. Fit sleeve into
case.
2. Lubricate shaft of first and
reverse gearshift cam and shaft
assembly. Fit cam and shaft assembly
to case in neutral position
(so
that the
interlock sleeve ball is in extended
detent notch of the cam).
3. Lubricate shaft of second and
third speed gearshift cam and
shaft
assembly. Fit the cam and
shaft
assembly to the case, pushing the cam
against the side of the case
so
that the
interlock sleeve hole is not blocked.
4.
Fit interlock pin, spring and
second ball. Move the cam and shaft
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