With FS5W71C & F4W71C Transmission

Case Components




1. Remove rear extension.
a. Remove control housing, check ball, return spring plug, select check plunger and return springs.




b. Remove rear extension by lightly tapping it.




2. Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing.




3. Separate transmission case from adapter plate.




4. Remove oil seal of front cover.
Be careful not to damage mating surface of front cover.

Shift Control Components




1. Set up Tool on adapter plate.
2. Remove check ball plugs, check springs, and check balls.




3. Drive out retaining pins. Then drive out fork rods and remove interlock balls.




4. Remove lever bracket securing bolt (4WD model with main shaft braking mechanism only).




5. Draw out 3rd-4th fork rod (4WD model only).




6. Remove E-ring from O.D.-rev. fork rod (4WD model only).




7. Draw out O.D.-rev. fork shaft by rotating O.D.-rev. bracket counterclockwise (4WD model only).

Gear Components







1. Before disassembly, measure each gear end play.
- If end play is not within the specified limit, disassemble and check the parts.
- Replace any part which is worn or damaged.




2. Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, sub-gear spring and sub-gear.




4. Draw out counter drive gear with main drive gear assembly with suitable puller.
- When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring.
5. Remove snap ring and draw out 3rd & 4th synchronizer and 3rd gear.




6. Disassemble parts at rear of adapter plate as follows.

- FS5W71C -
a. Release staking on countershaft nut and mainshaft nut and loosen these nuts.
Mainshaft nut: Left-hand thread




b. Pull out O.D. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, and draw out reverse idler gear, thrust washers and reverse idler gear bearing.







e. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring. (2WD model)
f. Remove mainshaft nut.
g. Remove speedometer drive gear and steel ball. (2WD model)
h. Remove thrust washer, steel roller, roller bearing and washer. Remove O.D. main gear, needle bearing and baulk ring (O.D.).
j. Remove O.D. coupling sleeve, shifting inserts and shifting insert springs.
k. Remove counter gear by tapping rear end of counter gear.
i. Press out O.D. gear bushing, insert retainer and O.D. synchronizer hub.




- F4W71C -
a. Remove snap rings, speedometer drive gear and steel ball.
b. Release staking on mainshaft nut and loosen it.
c. Remove mainshaft nut and reverse main gear.
d. Remove snap ring of countershaft rear end, and remove reverse counter gear.
e. Remove reverse idler gear.
f. Remove counter gear by tapping rear end of counter gear.




g. Draw out mainshaft assembly by tapping rear end of main- shaft.
7. Remove thrust washer, steel ball, 1st main gear and needle bearing.
Be careful not to lose steel ball.




8. Press out 1st gear mainshaft bushing together with 2nd main gear with Tool.
Then remove 2nd gear needle bearing.




9. Remove main drive gear bearing.
a. Remove snap ring and washer.
b. Remove main drive gear bearing.