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Diagnosis and repair



DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

{tag}1039394353@


17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

{tag}1039386504@


6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

{tag}1039379972@


3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

{tag}1039373138@


NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

{tag}1039344584@
Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.
DISASSEMBLE

Exploded View Of Transmissions (Part 1 0f 2)Exploded View Of Transmissions (Part 1 0f 2)

Description Of Exploded View Of Transmissions (Part 2 Of 2)Description Of Exploded View Of Transmissions (Part 2 Of 2)



NOTE: Refer to the Exploded View Of Transmissions image during transmission overhaul.

1.Place transmission in a suitable holding fixture, positioning front case downward.
2.Using a suitable chisel, bend tab back on output flange retaining nut

Output Flange To Mainshaft Attaching Nut RemovalOutput Flange To Mainshaft Attaching Nut Removal



3.Attach companion flange holding tool No. T87P-4851-A or equivalent to transmission output flange, then loosen output flange to mainshaft hex nut. Do not remove hex nut or output shaft flange.
4.Remove 15 of the 17 8 mm hex head front and rear case retaining screws. Leave 2 screws at opposite ends of case installed.
5.Remove any power take-off equipment installed on transmission.

Shift Tower RemovalShift Tower Removal



6.Remove eight 8 mm shift tower assembly-to-front case attaching bolts, then the gearshift lever, and tower as an assembly.
7.Remove interlock plate and compression spring which serves as a reverse gear interlock.

NOTE: Use care to ensure parts do not fall into transmission.

8.Place a suitable drift against the detent bolt sealing cap, then hold drift at an angle. Position point of drift off center of cap, then drive cap inward until spring pressure against underside of cap forces cap out of hole. Repeat this procedure for the other two detent bolt sealing caps in front case.

CAUTION: Use care as cap is under pressure and protective eyeglasses should be worn during this procedure.

9.Remove springs protruding from sealing cap holes, then drive out sealing caps for two reverse idler shaft cap screws. Remove reverse idler shaft cap screws.
10.If necessary, remove back-up lamp switch, then the back-up lamp switch sealing ring.
11.Remove two dowel pins, using a suitable drift, from upper corners of rear case to front case mating surfaces. Drive pins toward rear of case.
12.Remove two remaining hex bolts from rear case.
13.Carefully lift front case from rear case. It may be necessary to push central shift rail inward to prevent it from hanging up on front case. Use care to ensure central shift rail is not lifted with front case.

NOTE: Mating surfaces of two housing assemblies are coated with an adhesive. If difficult to separate, carefully tap front case with a soft hammer.

14.Remove central shift rail and shift finger assembly.
15.Lift shaft from reverse idler gear, then the gear and two caged roller bearings from rear case.
16.Remove three capscrews that retain shift interlock to rear case.

Lifting Sling InstallationLifting Sling Installation



17.Position transmission vertically on stand, then use nylon lifting sling D87L-1000-A or equivalent to strap gear pack holding fixture tool No, T87T-7025-HH or equivalent to mainshaft and output assemblies. Pass sling overshift rails.
18.Place shift rod support tool No. T87T-7025-JH or equivalent over ends of shift rails.
19.Carefully rotate transmission, together with gear pack holding fixture, into a horizontal position with holding fixture beneath gear pack.
20.Remove output shaft flange retaining nut from output shaft, then remove flange from output shaft, tapping with a soft hammer if necessary.
21.Pull gear pack and shift rails with holding fixtures forward and dislodge from rear case.
22.Remove speedometer drive gear from mainshaft, if equipped.
23.Remove sling from shift rails, gear pack, and holding fixture, then rotate gearshift rails approximately 45° and release from shift hubs. Lift gearshift rails, forks, and interlock with support tool from transmission
24.Position shift rail assembly with shift rails in vertical position, then remove interlock.
25.Mark each shift fork and shift rail to facilitate installation, then position in holding fixture. Lift shift rails from support tool.
26.Lift countershaft from bench stand then separate input shaft from main shaft.
27.Lift mainshaft and output shaft from stand, then remove rear cover from holding fixture.



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