Page 1737 of 2889
(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. 31).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig. 28 5-6 CROSSOVER
1 - 5-6 CROSSOVER BRACKET
Fig. 29 ATTACH FIXTURE 8232
1 - FIXTURE 8232
Fig. 30 HOLDING TOOL 8242
1 - HOLDING TOOL 8242
2 - 5-6 SYNCHRO
Fig. 31 SHIFT RAILS
1 - SHIFT RAILS
21 - 102 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)
Page 1738 of 2889

(10) Remove geartrain from the clutch housing and
install the geartrain into Support Stand 8246 (Fig.
32).
(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 Sleeve
6444-8, Adapters 6451, Puller Rods 6444-4 and Puller
6444 (Fig. 33).
(3) Remove rear countershaft bearing with Sleeve
6444-8, Adapters 6447, Puller Rods 6444-4, Puller
6444 and suitable press button (Fig. 34).
Fig. 32 LIFT GEARTRAIN WITH ENGINE CRANE
1 - FIXTURE 8232
2 - SUPPORT STAND 8246
Fig. 33 FRONT COUNTERSHAFT BEARING
1 - PULLER 6444
2 - ADAPTERS 6451
Fig. 34 REAR COUNTERSHAFT BEARING
1 - PULLER 6444
2 - ADAPTERS 6447
BR/BEMANUAL - NV5600 21 - 103
MANUAL - NV5600 (Continued)
Page 1739 of 2889

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, Adapters 8234, Puller Rods
6444-4 and the remainder of Puller 6444 (Fig. 35).
(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Sleeve 6444-8, Adapters 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. 36).
(2) Remove fifth gear friction cone from the input
shaft (Fig. 37).
Fig. 35 OUTPUT SHAFT POCKET BEARING
1 - PULLER 6444
2 - ADAPTERS 8234
Fig. 36 FIFTH GEAR BLOCKER RING
1 - FIFTH GEAR BLOCKER RING
2 - INPUT SHAFT
Fig. 37 FIFTH GEAR FRICTION CONE
1 - FIFTH GEAR FRICTION CONE
2 - INPUT SHAFT
21 - 104 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)
Page 1740 of 2889

(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 38).
(4) Remove input shaft bearing and oil guide from
the input shaft with Sleeve 6444-8, Adapters 8243,
Puller Rods 6444-6 and the remainder of Puller 6444
(Fig. 39).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be
installed backwards. To avoid assembly problems,
mark the gears, clutch gears, synchro hubs, and
sleeves for reference during teardown. Use paint or
a scriber for marking purposes. Then stack the
geartrain parts in order of removal. This practice
will help avoid incorrect assembly.
(1) Remove first gear from the output shaft.
(2) Remove first gear bearing from the output
shaft (Fig. 40).
(3) Remove first gear blocker rings (2) and cones
from the 1-2 synchro assembly (Fig. 41).
(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. 42).
(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.
Fig. 39 INPUT SHAFT BEARING
1 - PULLER 6444
2 - ADAPTERS 8243
Fig. 40 FIRST GEAR BEARING
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING
Fig. 38 OUTPUT SHAFT POCKET BEARING
1 - PULLER L-4518
2 - INPUT SHAFT
BR/BEMANUAL - NV5600 21 - 105
MANUAL - NV5600 (Continued)
Page 1741 of 2889

(9) Press the 5-6 synchro assembly from the out-
put shaft.
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 43).
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. 44).
(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. 45).
(6) Remove countershaft from the press and Fix-
ture 8227.
Fig. 41 FIRST GEAR BLOCKER RINGS
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICTION CONE
Fig. 42 SECOND GEAR 1-2 SYNCRO
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING SLEEVE
3 - SECOND GEAR
4 - FIXTURE
5 - 1-2 SYNCHRO 8227
Fig. 43 SIXTH GEAR COMPONENTS
1 - SIXTH GEAR FRICTION CONE
2 - SIXTH GEAR
3 - OUTPUT SHAFT
4 - SIXTH GEAR BLOCKER RING
5 - 5-6 SYNCHRO
21 - 106 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)
Page 1742 of 2889

(7) Remove fourth countershaft gear, friction cone,
blocker ring and bearing from the countershaft (Fig.
46).
(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
countershaft gear bearing sleeve from the counter-
shaft (Fig. 47).
(10) Remove countershaft from the press and Fix-
ture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 48).
(12) The 2-3 thrust washer should not normally
need to be removed from the countershaft. If neces-
sary slid 2-3 thrust washer off countershaft.
Fig. 44 FIFTH COUNTERSHAFT GEAR
1 - GUIDE 8235
2 - FIFTH COUNTER SHAFT GEAR
3 - FIXTURE 8227
Fig. 45 SIXTH COUNTERSHAFT GEAR
1 - GUIDE 8235
2 - SIXTH COUNTER SHAFT GEAR
3 - FIXTURE 8227
Fig. 46 FOURTH COUNTERSHAFT GEAR
1 - FOURTH GEAR BLOCKER RING
2 - FOURTH GEAR BEARING
3 - COUNTERSHAFT
4 - FOURTH GEAR FRICTION CONE
5 - FOURTH COUNTERSHAFT GEAR
BR/BEMANUAL - NV5600 21 - 107
MANUAL - NV5600 (Continued)
Page 1743 of 2889
CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 49).
(2) Remove countershaft oil guide from the coun-
tershaft front bearing bore in the clutch housing (Fig.
50).
(3) Remove countershaft front bearing race, end-
play shims, and spacer from the clutch housing with
Remover 6061-1 and Handle C-4171 (Fig. 51).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
(5) Remove input shaft oil guide and retainer seal
(Fig. 52).
Fig. 47 THIRD COUNTERSHAFT GEAR
1 - THIRD COUNTERSHAFT GEAR
2 - FIXTURE 8227
3 - 3-4 SYNCHRO
4 - BEARING SLEEVE
5 - COUNTERSHAFT
Fig. 48 THIRD GEAR BEARING
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR BEARING
Fig. 49 INPUT SHAFT RETAINER
1 - INPUT SHAFT RETAINER
2 - CLUTCH HOUSING
21 - 108 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)
Page 1744 of 2889

CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter
housing and gear case with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if
necessary.
INSPECTION - TRANSMISSION
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped or
worn. Replace the gear if the teeth are chipped,
cracked or worn thin.
Inspect the drive gear and bearings. Minor
scratches and burrs on the gear surfaces can be
reduced with an oil stone and 400 grit paper wetted
with oil. Replace either bearing if worn, or damaged.
Replace the gear if any teeth, splines, or bearing sur-
faces are also worn or damaged.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Minor corrosion, nicks, or pit-
ting can be smoothed with 400 grit emery and pol-
ished out with crocus cloth. Wet the abrasive paper
Fig. 50 COUNTERSHAFT OIL GUIDE
1 - CLUTCH HOUSING
2 - COUNTERSHAFT OIL GUIDE
Fig. 51 FRONT COUNTERSHAFT BEARING
1 - CLUTCH HOUSING
2 - HANDLE C-4171
3 - REMOVER 6061-1
Fig. 52 OIL GUIDE AND SEAL
1 - INPUT SHAFT OIL GUIDE
2 - INPUT SHAFT OIL SEAL
BR/BEMANUAL - NV5600 21 - 109
MANUAL - NV5600 (Continued)