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Unbolt the upper bolts using 12mm socket, the 2
long ones go on the 'bottom side' of the tranny. Once they are off, use a
soft mallet and either hit the ends of the case to loosen it or use a thin
screwdriver and CAREFULLY, without marring the alumnium, pry up the end cover. |
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Looking into the end case, you'll see a wave spring. Note its
orientation, there are 2 tabs on the back side of this washer, and it 'locks'
into the open space behind it (called the reverse bracket cone).
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At this angle, from left to right, is the Viscous Coupling (VC), 5th
intermediate gear, and 5th gear/synchro assembly
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Using snap ring pliers, remove the VC snap ring like so.
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Pull up the VC. It should come up easily. |
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Dont LOOSE THIS BALL! There will only be one, and either side of this
shaft has a hole, but only 1 ball. Save this ball.
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Using a punch/mallet, force the 5th gear synchro retaining pin out like
so. Save the pin
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Using a strong screwdriver,
stake out both of the nuts. It will take some work, but using a
hammer and some trick hitting, you can unstake em easily.
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Now the HARD part. There are plenty ways of doing this. I took the
cheap way. Force a penny or dime between the two 5th gears. This may
need two people to work. Have one person with a big screwdriver or a
bar, placed between the 2 gears, press down on the penny. Sort of
like if your benchpressing, but pushing downward. This will keep the
penny from slipping upward, while your trying to loosen the 2 big
nuts. As you see in the picture, anchor one of the wrenches on the
centershaft like so. This 'locks' the tranny and lets you unbolt the
input shaft nut. You may need to use a hammer on the wrench.
Do the same for the other nut, although you wont be able to stake the 2nd
wrench, locking the tranny. This is where the penny will help.
If you dont press down with the screwdriver/bar like said before, the
penny will keep poping upward. Or, just get an airgun :)
--Another slick way of doing this is buy poping off the 5th speed shift fork,
and pushing down the 5th speed synchro, locking 5th gear. Then choose any
other gear using the shift linkage (1st or 2nd may be better), and the tranny is
now locked. |
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Slip up the 5th speed synchro
and gear assembly. |
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Remember this order. Top
to bottom: Synchro, slider (the long angle and/or the lined'side
points towards the clutch), synchro, and 5th speed gear, with the smaller
diameter pointing away from the clutch, just like in the picture. |
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Hard to see, but the side of
this 5th speed HUB with the punch mark in the middle groove, goes toward
the clutch side. No worrys, as this hub and the other 2 hubs will
only press on ONE WAY, so you cant make a mistake. |
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These synchros have 3 grooves,
which mate up to the sliding pins on the hub. Just remember that
when putting them together later.
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Remove 5th speed intermediate
gear. You may be able to pull it up with your hands, or you may use
screw drivers, or a gear puller. Easy stuff.
|
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Remove these 3 Poppet plugs,
including the springs and balls inside. Also remove the Backuplight
switch (including its washer and ball). I used a magnet pen to pull
out the balls. Makes the job effortless.
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Using a mallet, or prying with
a screwdriver, pop up the top level (case adapter). Looking under
the adapter, you'll see 3 bearing races, each has a washer beneath used
for setting shaft tolerences. |
