Page 1801 of 2627

(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 27).
(3) Attach an engine crane or equivalent to Fixture
8232 and raise the geartrain approximately 1/4 in.
from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
(5) Lower the geartrain back into the clutch hous-
ing.
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn-
chro together during the removal operation.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
(8) Remove shift rails from the rest of the
geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig. 27 FIXTURE/OUTPUT SHAFT
1 - OUTPUT SHAFT
2 - FIXTURE
Fig. 28 Remove Holding Tool
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 29 SHIFT RAILS
1 - 5-6 SHIFT RAIL
21 - 98 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1802 of 2627

(10) Remove geartrain from the clutch housing and
install the geartrain into Support Stand 8246 (Fig.
30).
(11) Remove Fixture 8232 from the output shaft
and the countershaft.
(12) Separate the countershaft from the output
shaft.
(13) Separate the output shaft from the input
shaft. Hold the 5-6 synchro together while removing
the output shaft to prevent the synchro sleeve from
being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ring holding the front counter-
shaft bearing onto the countershaft.
(2) Remove front countershaft bearing with Collar
6444-8, Jaws 6451, Puller Rods 6444-4 and Puller
6444 (Fig. 31).
(3) Remove rear countershaft bearing with Collar
6444-8, Jaws 6447, Puller Rods 6444-4, Puller 6444
and suitable press button (Fig. 32).
Fig. 30 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
Fig. 31 FRONT COUNTERSHAFT BEARING
1 - PULLER
2-JAWS
Fig. 32 REAR COUNTERSHAFT BEARING
1 - PULLER
2-JAWS
DRMANUAL TRANSMISSION - NV5600 21 - 99
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1803 of 2627

OUTPUT SHAFT BEARINGS
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft
with Sleeve 6444-8, Jaws 8234, Puller Rods 6444-4
and the remainder of Puller 6444 (Fig. 33).
(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Collar 6444-8, Jaws 8271 and Puller Rods
6444-3 for 4X2 vehicles or Puller Rods 6444-4 for 4X4
vehicles with the remainder of Puller 6444 to remove
the rear output shaft bearing from the output shaft.
(5) Remove rear output shaft thrust washer from
the output shaft.
INPUT SHAFT
(1) Remove fifth gear blocker ring from the input
shaft (Fig. 34).
(2) Remove fifth gear friction cone from the input
shaft (Fig. 35).
Fig. 33 OUTPUT SHAFT POCKET BEARING
1 - PULLER
2-JAWS
Fig. 34 FIFTH GEAR BLOCKER RING
1 - FIFTH GEAR BLOCKER RING
2 - INPUT SHAFT
Fig. 35 FIFTH GEAR FRICTION CONE
1 - FRICTION CONE
2 - INPUT SHAFT
21 - 100 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1804 of 2627
(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
(4) Remove input shaft bearing and oil guide from
the input shaft with Collar 6444-8, Jaws 8243, Puller
Rods 6444-6 and the remainder of Puller 6444 (Fig.
37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be
installed backwards. Mark the gears, clutch gears,
synchro hubs, and sleeves for installation reference
during disassembly. Use paint or a scribe for mark-
ing purposes. Then stack the geartrain parts in
order of removal.
(1) Remove first gear from the output shaft.
(2) Remove first gear bearing from the output
shaft (Fig. 38).
Fig. 36 OUTPUT SHAFT POCKET BEARING RACE
1 - PULLER
2 - INPUT SHAFT
Fig. 37 INPUT SHAFT BEARING
1 - PULLER
2-JAWS
Fig. 38 FIRST GEAR BEARING
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING
DRMANUAL TRANSMISSION - NV5600 21 - 101
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1805 of 2627
(3) Remove first gear blocker rings (2) and cones
from the 1-2 synchro assembly (Fig. 39).
(4) Install the remainder of the output shaft into
Fixture 8227 with press blocks under second gear.
(5) Install shaft and Fixture assembly into a shop
press (Fig. 40).
(6) Press second gear, 1-2 synchro assembly and
first gear bearing sleeve from the output shaft.
(7) Remove second gear bearing from the output
shaft.(8) Reverse output shaft in the Fixture 8227 with
press blocks positioned under the 5-6 synchro assem-
bly.
(9) Press the 5-6 synchro assembly from the out-
put shaft.
Fig. 39 FIRST GEAR BLOCKER RINGS AND
FRICTION CONE
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICTION CONE
Fig. 40 SECOND GEAR, 1-2 SYNCHRO & FIRST
GEAR BEARING SLEEVE
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING SLEEVE
3 - SECOND GEAR
4 - FIXTURE
5 - 1-2 SYNCHRO
21 - 102 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1806 of 2627
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 41).
COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with
press blocks located under the fifth countershaft
gear.
(2) Place the assembly into a shop press.
(3) Use Guide 8235 on end of countershaft and
press the countershaft fifth gear from the counter-
shaft (Fig. 42).
(4) Place countershaft in Fixture 8227 with press
blocks placed under the sixth countershaft gear.
(5) Use Guide 8235 on end of countershaft and
press the countershaft sixth gear from the counter-
shaft (Fig. 43).
Fig. 41 SIXTH GEAR COMPONENTS
1 - SIXTH GEAR FRICTION CONE
2 - SIXTH GEAR
3 - OUTPUT SHAFT
4 - SIXTH GEAR BLOCKER RING
5 - 5-6 SYNCHRO
Fig. 42 FIFTH COUNTERSHAFT GEAR
1 - GUIDE
2 - FIFTH COUNTER SHAFT GEAR
3 - FIXTURE
Fig. 43 SIXTH COUNTERSHAFT GEAR
1 - GUIDE
2 - SIXTH COUNTER SHAFT GEAR
3 - FIXTURE
DRMANUAL TRANSMISSION - NV5600 21 - 103
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1807 of 2627

(6) Remove countershaft from the press and Fix-
ture 8227.
(7) Remove fourth countershaft gear, friction cone,
blocker ring and bearing from the countershaft (Fig.
44).
(8) Install countershaft into Fixture 8227 with
press blocks located under the third countershaft
gear.
(9) Place assembly into a shop press and press
third countershaft gear, 3-4 synchro and fourth coun-
tershaft gear bearing sleeve from the countershaft
(Fig. 45).
(10) Remove countershaft from the press and Fix-
ture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 46).
(12) The 2-3 thrust washer should not normally
need to be removed from the countershaft. If neces-
sary slide 2-3 thrust washer off countershaft.
Fig. 44 FOURTH COUNTERSHAFT GEAR
COMPONENTS
1 - FOURTH GEAR BLOCKER RING
2 - FOURTH GEAR BEARING
3 - COUNTERSHAFT
4 - FOURTH GEAR FRICTION CONE
5 - FOURTH COUNTERSHAFT GEAR
Fig. 45 THIRD COUNTERSHAFT GEAR
COMPONENTS
1 - THIRD COUNTERSHAFT GEAR
2 - FIXTURE
3 - 3-4 SYNCHRO
4 - BEARING SLEEVE
5 - COUNTERSHAFT
Fig. 46 THIRD GEAR BEARING
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR BEARING
21 - 104 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)
Page 1808 of 2627
CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 47).
(2) Remove countershaft oil guide from the coun-
tershaft front bearing bore in the clutch housing (Fig.
48).
(3) Remove countershaft front bearing race, end-
play shims and spacer from the clutch housing with
Remover 6061-1 and Handle C-4171 (Fig. 49).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
Fig. 47 INPUT SHAFT RETAINER
1 - INPUT SHAFT RETAINER
2 - CLUTCH HOUSING
Fig. 48 COUNTERSHAFT OIL GUIDE
1 - CLUTCH HOUSING
2 - COUNTERSHAFT OIL GUIDE
Fig. 49 FRONT COUNTERSHAFT BEARING RACE
1 - CLUTCH HOUSING
2 - HANDLE
3 - REMOVER
DRMANUAL TRANSMISSION - NV5600 21 - 105
MANUAL TRANSMISSION - NV5600 (Continued)