Remove and discard the output shaft o-ring (33) and four o-ring stud seals (41). Do not remove the studs (42)
unless the threads are stripped or damaged. Remove the capscrews (25) and sealing washers (26) and remove
the side cover (27). Discard the gasket (19).
Remove six capscrews (2) and sealing washer (3) and remove the shift cap assembly (1). Discard the gasket
(19). Remove shifting forks (9 and 10). Drive out the two retainer pins (4) and remove the shift arms (5);
remove oil seals (6).
Lay the shift cap assembly in a fixture with the inside of the cap up. In this position the steel
balls and springs will better stay in place. As you disassemble the shift cap, take note of how
the parts are positioned in the cap. This will aid at reassembly.
Remove the safety wire (7) and unscrew two drilled-head capscrews (8). Carefully, remove the inhibitor block
(11), then remove the steel ball (12) from between the shift selectors (13). Remove the two assembled shift
selectors and two steel balls (12) and springs (14) from the shift cap (17). Do not remove the shift stop pins (15)
unless they are damaged and must be replaced. To disassemble the shift selectors, drive out the retainer pin (4)
from the selector (13); then separate the selector (13) and shift shaft (16).
Remove the output shaft bearing (43), thrust washer (44) and thirty-four roller bearings (45). Begin removing the
gears by carefully extracting the countershaft (51) from the case. (Bearing (50) is pressed onto the countershaft
and bearing (59) is pressed into the housing.) As you remove the shaft from the rear of the transmission, remove
the drive gear (58), third gear (57), shifting collar hub (55), shifting collar (54), and second gear (53) from the
side of the transmission. (Four press-fitted bearings (52) and bearing sleeve (56) will come out with the gears.)
Complete the disassembly process by removing the output shaft (49) from the front of the transmission while
removing the gears (46, 47, 48) from the side.
4-10.3.3 Cleaning, Inspection, and Repair.
Clean all parts thoroughly in an approved cleaning solvent. Clean again with clean solvent before reassembling.
Handle parts with care. Nicks, scratches, or dents caused by careless handling can cause subsequent
Never dry bearings with compressed air and do not spin bearings that are not lubricated.
Check shafts and bores for nicks and scratches.
Check gears for nicks, burrs, or broken or worn teeth.