Page 2617 of 5267
2. Remove mainshaft center support (1) bearing race
with Remove/Installer 9668 (2) and Handle C4171.
3. Remove countershaft center support (1) bearing
race with Remove/Installer 9617 (2) and Handle
C4171.
Page 2618 of 5267
FRONT HOUSING
1. Remove mainshaft bearing retainer (1) and coun-
tershaft bearing retainers (2).
2. Remove mainshaft bearing and countershaft bear-
ing with hammer and driver.
REAR HOUSING
1. Remove reverse idler gear shaft bolt (1) from hous-
ing (2).
Page 2619 of 5267
2. Remove reverse idler gear shaft (1) from idler gear
(2).
3. Remove reverse idler gear (1) shaft support (2).
4. Remove reverse idler gear (1) and bearing (2).
Page 2620 of 5267
5. Remove mainshaft bearing (1) retainer (2) bolts
and remove retainer.
6. Remove bearing from housing with a hammer and
driver.
7. Break plastic countershaft roller bearing cage with
a screw driver. Then remove cage and roller bear-
ing.
8. Insert Puller 9585 through the countershaft roller
bearing shell (1) and expand the tool (2) to grab
the bottom (3) of the bearing shell (1).
9. Remove countershaft roller bearing shell (1) from
the rear housing with Puller 9585 (2) and Slide
Hammer C-637.
Page 2621 of 5267

10. Remove shift rail roller bearing from rear housing
(3) with Puller 9609 (1) and Slide Hammer C-637
(2).
CLEANING
Clean gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use
acid or corrosive base solvents. Dry all parts except bearings with compressed air.
Clean shaft bearings with a mild solvent such as MOPAR
degreasing solvent, Gunkor similar solvents. Do not
dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out
with crocus cloth.
Bearings:Inspect roller bearings for wear, chips,
cracks, flat-spots or brinnelling. Inspect sealed bear-
ings, and verify bearings roll smoothly.
Gears:Inspect for worn, chipped, or cracked teeth.
Inspect bearing surfaces for wear or flat-spots.
Mainshaft:Inspect for worn splines (1), snap ring
grooves (2) and worn, chipped or cracked teeth (3).
Inspect all bearing surfaces (4) for wear or flat-spots.
Third and fourth gear (3) are serviced with
mainshaft.
Page 2622 of 5267
Countershaft:Inspect all gears for worn, chipped or
cracked teeth (1). Inspect 3-4 synchronizer assembly
for wear (2). Inspect center support bearing surfaces
(3) for wear or flat-spots.The countershaft with 3-4
synchronizer is serviced as an assembly, except
for bearings.
Synchronizer components:Inspect for worn,
chipped, or cracked teeth and burned or flaking off
friction material.Synchronizers are serviced as an
assembly.
Input Shaft:Inspect input shaft bearing (1) and bear-
ing surfaces for wear or flat-spots. Inspect input shaft
splines (2) for wear. Inspect snap ring groove (3) for
wear. Inspect fifth gear (4) for worn, chipped, or
cracked teeth.
Shift forks:Inspect shift forks (1) for distortion.
Inspect fork shoes (2) for wear and fit shoes in syn-
chronizer sleeve to ensure parts fit and work smoothly.
Page 2623 of 5267
Shift Rails:Inspect shift rails, bushings, and bearing
for wear. Verify main shift rail (1) bearings (2) roll
smoothly.
Clutch Release Bearing Support:Inspect clutch
release bearing support (1) release bearing slide sur-
face (2) for damage.
Housing/Tail housing:Inspect sealing and mating
surfaces are free of burrs and nicks. Inspect alignment
dowels are tight and in good condition. Inspect shift
rail bushings for wear.
Page 2624 of 5267
ASSEMBLY
MAINSHAFT
1. Install mainshaft center support bearing (1) on
mainshaft (2).
2. Install sixth gear bearing (1) on mainshaft (2).