Tools Required

J 8433  Two Jaw Puller. See Special Tools .

Fig 1: View Of Drain Plug
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IMPORTANT: The following steps apply to both the 4WD and the RWD transmission, except where noted.
1. Remove the drain plug, with aluminum washer, and drain the transmission fluid.
Fig 2: View Of Vehicle Speed Sensor (VSS) With O-Ring Seal - RWD
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2. If RWD, remove the vehicle speed sensor with O-ring seal.
Fig 3: View Of Backup Lamp Switch
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3. Remove the backup lamp switch, with the aluminum washer, from the front case.
Fig 4: Identifying Clutch Housing Retaining Bolts
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4. Remove the 9 bolts retaining the clutch housing.
5. Using a soft-face hammer, remove the clutch housing from the transmission assembly.
Fig 5: Locating Shift Control Housing & Gasket
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6. Shift the transmission into NEUTRAL.
7. Remove the shift control housing bolts.
8. Remove the shift control housing.
9. Remove the shift control housing gasket.
Fig 6: View Of Shift Control Lever Socket Bolt
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10. Remove the shift control lever socket bolt.
Fig 7: Identifying Extension Housing Retaining Bolts And Studs
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11. Mark the location of the brackets and the studs.
12. Remove the extension housing retaining bolts, studs, and brackets.

    The 4WD does not use a bracket on the left side of the transmission.

Fig 8: Locating Shift Control Socket At Extension Housing Shift Lever Cavity
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NOTE: Refer to Machined Surface Damage Notice .
13. Using a soft-face hammer, separate the extension housing from the intermediate case.
14. Slide the extension housing off the shift control shaft.
15. Remove the shift control socket from the extension housing shift lever cavity.
Fig 9: Identifying Shift Control Shaft
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16. Remove the shift control shaft from the shift shaft gates.
Fig 10: Locating Input Shaft Bearing Retainer Bolts
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17. Remove the front bearing retainer bolts. Discard the bolts. New bolts are required for assembly.
18. Remove the front bearing retainer.
Fig 11: Removing/Installing Input Shaft Seal
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19. Using a suitable punch and a hammer, remove the input shaft seal from the bearing retainer. Do not use the seal again.
Fig 12: Locating Outer Retaining Rings On Input Shaft Bearing & Countershaft Front Bearing
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20. Remove the outer retaining ring from the input shaft bearing.
21. Remove the outer retaining ring from the countershaft front bearing.
Fig 13: Shearing Sealer On Transmission Front Case
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NOTE: Refer to Machined Surface Damage Notice .
22. Using a soft-face hammer on the transmission front case, shear the sealer.
23. Remove the transmission front case from the intermediate case.
Fig 14: Locating Oil Baffle Bolts
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24. Remove the oil baffle bolts.
25. Remove the oil baffle.
Fig 15: View Of Transmission Magnet
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26. Remove the magnet.
Fig 16: Installing Intermediate Case Temporary Mounting Bolts
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NOTE: Refer to Machined Surface Damage Notice .
27. Install 2 bolts, with nuts, in the lower holes of the intermediate case. The bolts will be used to hold the intermediate case in a vise during disassembly and assembly.
Fig 17: Measuring Axial Clearance On 5th Synchronizer Gear
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IMPORTANT: Before removal of the 5th synchronizer gear, measure the axial play of the speed gear. Incorrect axial play of the gear may cause shifting concerns or transmission noise.
28. Using a feeler gage between the 5th countershaft gear and the thrust washer, measure the axial clearance.

    Specification: 

    • Standard Clearance: 0.10-0.35 mm (0.0039-0.0138 in)
    • Maximum Clearance: 0.40 mm (0.0157 in)

29. If the clearance exceeds the maximum, refer to Gears and Shafts Cleaning and Inspection .
Fig 18: Removing/Installing 5th Synchronizer Gear Retaining Ring
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30. Mount the intermediate case assembly in a vise on the 2 previously installed bolts.
31. Using 2 screwdrivers and a hammer, remove the 5th synchronizer gear retaining ring.
Fig 19: Removing 5th Synchronizer Gear Using J 8433
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32. Using J 8433  with 2 bolts in the threaded holes of the 5th synchronizer gear, remove the gear. See Special Tools .
Fig 20: View Of 5th/Reverse Gear Synchronizer
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33. Remove the 5th/reverse gear synchronizer.
Fig 21: Removing/Installing 5th Shift Fork Roll Pin
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34. Using a hammer and a punch, remove the 5th shift fork roll pin.
Fig 22: View Of 5th/Reverse Synchronizer Assembly & 5th Countershaft Gear Bearing
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35. Remove the shift fork, the 5th/reverse synchronizer sleeve and blocking ring assembly and the 5th countershaft gear and bearing.
Fig 23: Locating 5th Gear Thrust Washer
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36. Remove the 5th countershaft gear thrust washer.
37. Remove the thrust washer lock pin.
Fig 24: Identifying Rear Bearing Retainer & Retaining Bolts
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38. Remove the bolts for the rear bearing retainer.
39. Remove the rear bearing retainer.
Fig 25: Identifying Outer Retaining Ring On The Countershaft Rear Bearing
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40. Using a soft-face hammer, tap the countershaft rearward to expose the outer retaining ring on the countershaft rear bearing.
41. Using a suitable prying tool on the retaining ring, remove the countershaft rear bearing. The bearing will slide out of the case if the countershaft is kept in position with the output shaft.
Fig 26: View Of Countershaft
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42. Remove the countershaft.
Fig 27: Locating Reverse Gear Idler Shaft And Reverse Idler Gear
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43. Remove the reverse idler gear shaft and reverse idler gear.
Fig 28: View Of Input Shaft Assembly
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44. Remove the input shaft assembly, with the 4th gear blocking ring, and output shaft front support bearing from the output shaft.
Fig 29: Identifying Shift Fork Bolts
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45. Remove the 1st/2nd shift fork bolt.
46. Remove the 3rd/4th shift fork bolt.
Fig 30: Locating Retaining Ring For The Reverse Shift Lever
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47. Remove the retaining ring for the reverse shift lever on the reverse shift shaft.
    • Use a suitable pair of pliers to push the retaining ring.
    • Only push the retaining ring partially off to keep it from flying.
    • Use a pair of pliers to remove the retaining ring the rest of the way.
Fig 31: View Of Retaining Ring Groove On The Reverse Shift Shaft
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48. Shift the reverse shift shaft forward.
49. Move the reverse shift lever forward past the retaining ring groove on the reverse shift shaft. This allows clearance of the reverse shift fork during removal of the output shaft.
Fig 32: View Of Output Shaft Rear Bearing Outer Retaining Ring
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50. Remove the output shaft rear bearing outer retaining ring.
Fig 33: Identifying Output Shaft Assembly
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51. Remove the output shaft assembly.
    • Hold the 1st/2nd shift fork and the 3rd/4th shift fork in position to the output shaft.
    • Slide the 1st/2nd shift fork and the 3rd/4th shift fork off the shift shafts while removing the output shaft.
Fig 34: Locating Shift Shaft Detent Plugs
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IMPORTANT: If the shift shafts or the intermediate case do not require service, proceed to Output Shaft Disassemble. If the shift shafts or intermediate case require service, proceed to the next step.
52. Remove the 4 shift shaft detent plugs for the shift detent balls and springs. Discard the plugs. New plugs are required for assembly.
Fig 35: View Of Shift Shaft Detent Springs And Balls
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53. Using a magnet, remove the 1st/2nd shift shaft detent spring and ball.
54. Using a magnet, remove the 3rd/4th shift shaft detent spring and ball.
55. Using a magnet, remove the 5th shift shaft detent spring and ball. The reverse shift shaft does not have a detent spring and ball in the plug opening.
Fig 36: Locating Shift Shaft Retaining Rings
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IMPORTANT: To prevent the retaining rings from flying, cover the area with a rag.
56. Remove the following shift shaft retaining rings:
    • The 1st/2nd shift shaft
    • The 3rd/4th shift shaft
    • The 5th shift shaft
      • Use a suitable pair of pliers to push the retaining ring.
      • Only push the retaining ring partially off to keep it from flying.
      • Use a pair of pliers to remove the retaining ring the rest of the way.
Fig 37: Identifying 3rd/4th Shift Shaft
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57. Remove the 3rd/4th shift shaft.
Fig 38: Locating 1st/2nd Shift Shaft
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58. Using a magnet, remove the 1st/2nd and 3rd/4th shift shaft interlock pin.
59. Remove the 1st/2nd shift shaft.
60. Remove the small interlock pin from the 1st/2nd shift shaft.
Fig 39: View Of 5th Shift Shaft & Detent Ball
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61. Using a magnet, remove the 5th shift shaft and 1st/2nd shift shaft interlock pin.
62. Remove the 5th shift shaft.
Fig 40: Identifying Detent Ball In The Reverse Shift Lever
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63. Remove the detent ball from the reverse shift lever.
Fig 41: Locating Detent Spring & Ball
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64. Remove the reverse shift lever, with the reverse shift fork, from the reverse shift shaft.
    1. Slide the shift lever to the end of the shaft.
    2. Cover the detent ball opening with your hand.
    3. Let the detent ball and spring land in your hand.
Fig 42: Locating Reverse Gear Shift Shaft
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65. Using a magnet, remove the interlock pin from the reverse shift shaft. The shaft may require moving back and forth to remove the interlock pin.
66. Remove the reverse shift shaft.
Fig 43: Installing/Removing Reverse Shift Fork Bracket And Bolts
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67. Remove the bolts and the reverse shift fork bracket.