TRANSMISSION UPGRADES: DISASSEMBLING YOUR TRANSMISSION
NOTES:
When Anti-Seize compound is called for, just a light film is all that is needed to help press-fit parts go togeather easier.

When using a press to install or remove gears, it is best to hold gear by the hub. If this is not possible, use copper or aluminum bars for contact against teeth to avoid damage. Do not pry against gear teeth, chipping may occur.

 
3-7.  GENERAL:
  • Clean the exterior of the transmission; the cleaner it is, the easier it will be to work on it without having pieces of crud or dirt contaminate the inner workings.

  • When a transmission is repaired, it must be disassembled completely so that the parts may be thoroughly cleaned and inspected for wear or damage.

  • Disassembly is accomplished in two stages: first, disassembly into subassemblies; second, disassembly of the subassemblies.

  • Disassembly of the transmission is accomplished by following logical step-by-step procedures. Paragraph 3-8 provides disassembly to the subassembly level, paragraph 3-9 provides the disassembly procedures from the subassembly level to the piece part. Assembly procedures are given only where special attention to a part or assembly is required or needed. The assembly of the transmission is the exact opposite of disassembly except where otherwise specified for clarity. Always use new gaskets and seals during assembly.


 
3-8.  DISASSEMBLY OF TRANSMISSION INTO SUBASSEMBLIES:
A. CLUTCH RELEASE ASSEMBLY -
  1. Remove the two capscrews and lockwashers securing the clutch release yoke to the clutch shaft. Partially slide the clutch release shaft through the clutch bell housing and remove the two yoke keys from the shaft. Remove the clutch release yoke from the shaft and complete the removal of the clutch release shaft from the clutch housing. You can leave the release bearing attached to the yoke unless you are replacing it.


  2. OPTIONAL: Remove the five capscrews and lockwashers securing the clutch bell housing to the transmission case. Remove clutch bell housing and gasket from the face of the transmission case.
NOTE: It is not necessary to remove the bell housing unless you want to replace the gasket.
 
B. SHIFTER SHAFT COVER -
NOTE: It is easier to remove the transmission if you take the top cover off in the truck.
Position the transmission shifter shaft in neutral. Remove the eight capscrews and washers securing the shifter shaft cover, and lift straight up to clear transmission case.
 
C. COUNTERSHAFT REAR BEARING COVER -
Remove the four capscrews and lockwashers securing the countershaft rear bearing cover to the transmission case. Remove the countershaft rear bearing cover and gasket.
 
D. COMPANION FLANGE -
Slide the gears on the mainshaft to lock the transmission. Remove the cotterpin from the mainshaft nut. Remove the retaining nut securing the companion flange to the mainshaft. Also remove the cotter pin and nut securing the rear bearing to the countershaft. Use the universal puller remove the companion flange. Take care not to damage the surface where the seal runs.
 
E. MAINSHAFT REAR BEARING CAP ASSEMBLY -
Remove the four capscrews and lockwashers securing the bearing cap assembly to the transmission case. Remove the bearing cap assembly, spacer, and gasket.
 
F. INPUT SHAFT BEARING CAP -
Remove the four capscrews and lockwashers securing the input shaft bearing cap to the transmission case. Using a block of wood, drive the input gear forward about 1/4" to start the bearing cap moving. Remove the input shaft bearing cap, the snap ring around the outside of the bearing, and gasket.
 
G. MAINSHAFT REAR BEARING -
Move the mainshaft rearward to move the rear bearing snap ring out from the case then use a universal puller to remove the rear bearing from the mainshaft.

(Click on image for larger view)
Now move the mainshaft to the rear and out of the input shaft. Roller bearings from front of mainshaft will fall into bottom of case. You will retrieve them later.
 
H. FOURTH- AND FIFTH-SPEED SYNCHRONIZER -
Lower the rear of the mainshaft and lift the front to be able to slide the fourth- and fifth-speed synchronizer from the mainshaft.
 
I. MAINSHAFT ASSEMBLY -
Tilt the front of the shaft upward and slide the mainshaft from the first and reverse gear, leaving the gear in the case.
 
J. INPUT SHAFT -
Remove the input shaft from the inside of case, towards the rear of the transmission after removing the mainshaft. If there are rollers remaining in the input shaft just let them fall into the case.
 
K. COUNTERSHAFT -
Slide the countershaft rearward out of the front bearing. Extend the shaft out through the rear bearing bore. Use a universal puller to remove the rear bearing from the countershaft.

(Click on image for larger view)
Then remove the countershaft assembly from inside the transmission case.

 
3-9.  DISASSEMBLY OF SUBASSEMBLIES:
A. INPUT SHAFT ASSEMBLY -
If you are replacing the input shaft ball bearing, using a pair of pliers, remove the input shaft ball bearing retainer snap ring. Place the input shaft between two parallel blocks, spline upward. Using an arbor press, push the input shaft ball bearing from the shaft.
 
B. MAINSHAFT DISASSEMBLY -
  1. Remove the snap ring and fifth-speed gear thrust washer from mainshaft assembly. Slide the fifth-speed gear from the mainshaft.
  2. Setup in press to remove third speed gear. Apply pressure from the press ram to remove fifth-speed gear sleeve and third-speed gear together.
  3. Slide second- and third-speed synchronizer free of mainshaft. Using a pair of pliers, remove the snap ring which holds the second-and third-speed synchronizer sleeve in position. Set up press to remove second speed gear and use it to move second- and third-speed synchronizer sleeve approximately ¼ inch only.
  4. STOP - Do not press second-speed gear onto woodruff keys of mainshaft! Now place the a bearing separator on second and third speed synchronizer sleeve. Continue to remove synchronizer sleeve from shaft and remove the two woodruff keys, then remove second-speed gear.
 
C. COUNTERSHAFT ASSEMBLY -
Using a pair of pliers, remove front snap ring. Move snap ring for fifth gear forward and up behind the input gear and line up the gap with the keyway. Install a puller adapter under countershaft fifth gear and press the shaft from both gears at same time.
 
D. MAINSHAFT REAR BEARING CAP -
Using a round suitable block, drive the oil seal from the bearing cap.

 
If you have any questions, or want to order a kit, please call us at (410) 549-6649.

This page last updated 05-14-2012
Tom Bauer (410) 549-6649 waterloospecialties@hughes.net