Special Tools
- DT-03289-20 Holding Fixture
- DT-38416-B Harmonic Balancer Remover
- DT-45019 Flange and Pinion Cage Remover
- DT-47678 Transmission Holding Fixture
- DT-47678-10 Transmission Holding Fixture Adapter
- DT-49139 Hub Puller Adapter
- GE-6125-1B Slide Hammer with Adapter
- GE-8433 Universal Bridge Puller
- J-22888-20A Universal Two Jaw Puller
- J-39431-A 5th and 6th Driven Gear Puller
- J-39431-3 Fifth Gear Puller Adapter Bolts
- J-45012 Pinion Flange Holder
Equivalent regional tools: Special Tools
- Drain the fluid from the transmission. Transmission Fluid Drain and Fill
- Remove the transmission. Manual Transmission Removal and Installation
Install the DT-47678 Transmission Holding Fixture (2) and the DT-47678-10 Transmission Holding Fixture Adapter (3) to the transmission (4).
- Mount the transmission (4) on a workbench using the DT-03289-20 Holding Fixture (1).
- Rotate the transmission (4) into a horizontal position.
- Shift the transmission into NEUTRAL (N).
Shift Control Shaft Cover Bolt (3) - Remove and DISCARD [4x]
- Shift Control Shaft Cover (2) - Remove
- Shift Control Shaft Cover Seal (1) - Remove and DISCARD
Install the DT-45012 Pinion Flange Holder (4) to the propeller shaft transmission yoke (3).
- Using a socket wrench, remove and DISCARD the propeller shaft transmission yoke nut (1).
- Propeller Shaft Transmission Yoke Washer (2) - Remove and DISCARD
Using the DT-45019 Flange and Pinion Cage Remover (2), remove the propeller shaft transmission yoke (1).
- NOTE:
Only remove the bolts from the gear position sensor plate. Do NOT remove the 2 bolts from the sensor.
Manual Transmission Gear Position Sensor Bolt (1) - Remove and DISCARD [4x]
- Manual Transmission Gear Position Sensor (2) - Remove
- Manual Transmission Gear Position Sensor Seal (3) - Remove and DISCARD
Shift Shaft Detent Lever Bolt (2) - Remove
- Shift Fork Position Sensor Magnet (1) - Remove
Transmission Extension Bolt (1) - Remove and DISCARD [6x]
- Transmission Extension Nut (2) - Remove and DISCARD [2x]
- Transmission Fluid Auxiliary Cooler Pipe Bracket (3) - Remove
- Transmission Fluid Cooler Upper Extension Pipe Clip Bracket (4) - Remove [2x]
- Transmission Extension (5) - Remove
- Transmission Extension Gasket (6) - Remove and DISCARD
Shift Shaft Detent Plug (1) - Remove and DISCARD
- Shift Shaft Detent Spring (2) - Remove
- Shift Shaft Detent Roller (3) - Remove
Using a suitable tool, remove and DISCARD the 1st and 2nd shift fork pin (2).
- Remove the offset shift lever (1).
Remove and DISCARD the main shaft bearing retaining ring (1).
- Using the EN-38416-B Harmonic Balancer Remover (3), remove the vehicle speed sensor reluctor wheel (2).
Main Shaft Bearing Retaining Ring (1) - Remove and DISCARD
- Reverse Gear Thrust Washer (3) - Remove [2x]
- Main Shaft Rear Bearing (2) - Remove
Main Shaft Bearing Retaining Ring (1) - Remove and DISCARD
- Reverse Gear Thrust Washer (2) - Remove
- Reverse Gear (3) - Remove
- Reverse Gear Bearing (4) - Remove
- Remove the reverse gear blocking ring (5), which includes the following components:
- Reverse gear synchronizer inner cone
- Reverse gear synchronizer outer cone
- Reverse Gear Blocking Ring
Reverse Gear Retaining Ring (2) - Remove and DISCARD
- Reverse Shift Fork Retaining Ring (1) - Remove and DISCARD
Scribe a mark on the reverse gear synchronizer hub (1) and on the reverse gear synchronizer sleeve (2). This will help you to reinstall the parts in the same position.
Remove the reverse shift fork, synchronizer and inserts (1).
- 5th Gear Thrust Washer (2) - Remove and DISCARD
- Remove the two piece reverse gear retaining ring (3).
Counter Drive Gear Retaining Ring (1) - Remove and DISCARD
- Using the J-22888-20A Universal Two Jaw Puller (3), remove the reverse counter gear (2).
5th Gear Retaining Ring (1) - Remove and DISCARD
- 5th Gear Thrust Washer (2) - Remove
- 5th Gear (3) - Remove
- 5th Gear Bearing (4) - Remove
- 5th Gear Bearing Spacer (5) - Remove
- NOTE:
Ensure the remover tools are aligned level to pull the gear evenly off the shaft.
Setup the following tools:
- GE-8433 Universal Bridge Puller (2)
- DT-39431-3 Fifth Gear Puller Adapter Bolts (3)
- DT-39431-A 5th and 6th Driven Gear Puller (4)
- 5th Gear (1) - Remove
5th and 6th Gear Synchronizer Hub Retaining Ring- Small (5) - Remove and DISCARD
- Remove the following 5th and 6th synchronizer components (1):
- 5th gear synchronizer inner cone
- 5th gear synchronizer outer cone
- 5th Gear Blocking Ring
- 5th and 6th Shift Fork (2) - Remove
- 5th and 6th Gear Synchronizer Sleeve (4) - Remove
- 5th and 6th Gear Synchronizer Insert (3) - Remove [3x]
Using the DT-49139 Hub Puller Adapter (2) and GE-6125-1B Slide Hammer with Adapter (1), remove the 5th and 6th synchronizer hub (3).
Remove the following 6th gear blocking ring components (1):
- The 6th gear blocking ring.
- The 6th gear synchronizer outer cone.
- The 6th gear synchronizer inner cone
5th and 6th Gear Synchronizer Hub Retaining Ring- Large (1) - Remove and DISCARD
- 6th Gear (2) - Remove
- 6th Gear Bearing (3) - Remove
- 6th Counter Gear Spacer (4) - Remove
- 6th Gear Thrust Washer (5) - Remove
- Remove and DISCARD 9 of the 11 clutch housing adapter bolts (1) from the transmission case.
- Rotate the transmission into the vertical position.
Shift Shaft Interlock Pin (2) - Remove and DISCARD [2x]
- Remove and DISCARD the last 2 clutch housing adapter bolts (1).
Transmission Magnet (1) - Remove
Drive out the 1st and 2nd shift fork pin and DISCARD (3).
- Remove the transmission case (1) and the offset shift lever (2) together as follows:
- Slide the transmission case (1) up and off of the gear clusters and the shift shaft components.
- Hold the select control lever (2) against the guide plate in order to prevent the release of the detent ball and the spring.
- Remove the offset shift lever (2) from the transmission case.
- Clutch Housing Gasket (4) - Remove and DISCARD
Transmission Fluid Pump Inlet Pipe (1) - Remove
- Transmission Fluid Pump Inlet Pipe Seal (2) - Remove and DISCARD
Pull up on the 3rd and 4th shift fork (2) and rotate the 5th and 6th and the reverse shift shaft levers (1) off the shift interlock plate.
- 5th and 6th and Reverse Shift Shaft (1) - Remove
Lift up the main shaft (2) enough in order to remove the counter gear (1).
Remove the main shaft (1) and the shift shaft components (2) as an assembly.
- Remove the shift shaft (2) from the main shaft (1).
Remove the 4th gear blocking ring, which includes the following components (2):
- 4th Gear Blocking Ring
- 4th Gear Synchronizer Outer Cone
- 4th Gear Synchronizer Inner Cone
- Input Shaft (1) - Remove