Transmission Disassembly

1. Remove back-up light switch and clutch cable bracket. Remove bolts, springs and steel balls from transmission cover. Remove reverse idler gear shaft bolt. Remove all housing bolts and 32-mm sealing bolt (32-mm bolt has square hole).
2. Remove snap ring under 32-mm bolt. Separate transmission housings. Remove thrust shim and oil guide plate from housing. See Fig 1 and Fig 2 . Remove 16-mm sealing bolt (bolt has hex hole). Remove oil gutter plate.
3. Measure clearance between reverse shift fork and 5th/reverse shift piece pin. See Fig 3 . Clearance for reverse side (top of "L" groove) should be .002"-.018" (.05-.45 mm). Clearance for 5th side should be .016-.035" (.40-.90 mm).
4. If clearance exceeds specification, measure width of groove in reverse shift fork. Width for reverse side should be .278-.285" (7.05-7.25 mm). Width for 5th side should be .291-.303" (7.40-7.70 mm). If width of groove exceeds specification, replace reverse shift fork. If width of groove is within specification, replace 5th/reverse shift piece.
5. Measure clearance between reverse idler gear and reverse shift fork. See Fig 5 . Clearance should be .020-.043" (.50-1.10 mm). Service limit is .071" (1.80 mm). If clearance exceeds service limit, measure width of reverse shift fork pawl groove. Opening should be .512-.524" (13.0-13.3 mm). If width exceeds specification, replace reverse shift arm. If width is within specification, replace reverse shift fork.
6. Remove reverse shift fork. Shift 3rd/4th shift fork to the 4th side. Remove reverse idler gear and shaft. Measure clearance between shift piece and shift arm. Clearance should be .004-.012" (.10-.30 mm). Service limit is .0245" (.60 mm). If clearance exceeds service limit, measure width of groove in shift piece. See Fig 7 . Width should be .319-.323" (8.10-8.20 mm). If width of groove exceeds specification, replace shift piece. If width of groove is within specification, replace shift arm.
7. Measure clearance between select arm and interlock. Clearance should be .002-.010" (.05-.25 mm). Service limit is .020" (.50 mm). If clearance exceeds service limit, measure width of interlock. See Fig 9 . Width should be .390-.394" (9.90-10.00 mm). If width exceeds specification, replace select arm. If width is within specification, replace interlock.
8. Measure clearance between select arm and shim. Clearance should be .0004-.008" (.08-.20 mm). See Fig 11 . If clearance exceeds specification, select appropriate thrust shim for correct clearance. See THRUST SHIM  table.
   THRUST SHIM
   
   

   Part Number	Thickness
   24435-689-000	.031" (.80 mm)
   24436-689-000	.039" (1.00 mm)
   24437-689-000	.047" (1.20 mm)
   24438-689-000	.055" (1.40 mm)
   24439-689-000	.063" (1.60 mm)

9. Measure clearance between shift arm holder and change piece. Clearance should be .002-.014" (.05-.35 mm). Service limit is .031" (.80 mm). See Fig 12 . Width should be .474-.478" (12.05-12.15 mm). If clearance exceeds service limit, measure groove of change piece. If groove exceeds specification, replace change piece. If groove is within specification, replace change piece.
10. Measure clearance between select arm and change piece. Clearance should be .002-.010" (.05-.25 mm). Service limit is .020" (.50 mm). See Fig 12 . If clearance exceeds service limit, measure width of select arm. Width should be .474-.478" (12.05-12.15 mm). If width exceeds specification, replace select arm. If width is within specification, replace change piece.
11. Remove shift piece shaft, then remove shift piece and interlock. Remove change holder assembly. Tape mainshaft spline for protection. Remove mainshaft and countershaft assemblies with shift fork from clutch housing. Remove differential assembly. Remove camber plate. Remove shift rod change piece bolt and spring washer. Remove set bolt, spring and steel ball. Remove shift rod, then remove change piece.
12. Measure clearance between synchro sleeve and shift fork. Clearance should be .018-.026" (.45-.65 mm). Service limit is .039" (1.0 mm). If clearance exceeds service limit, measure width of shift fork fingers. Clearance should be .291-.295" (7.4-7.5 mm). If width of shift fork fingers exceeds specification, replace shift fork. If width of shift fork fingers is within specification, replace synchro sleeve. Synchro sleeve and synchro hub should always be replaced together.
13. Measure clearance between shift piece and shift fork shafts. Clearance should be .008-.020" (.20-.50 mm). Service limit is .031" (.80 mm). See Fig 16 . If clearance exceeds service limit, measure width of shift piece. Clearance should be .469-.472" (11.9-12.0 mm). If width of shift piece exceeds specification, replace shift fork. If width is within specification, replace shift fork shaft.