Insrtuctions for 5-Speed Installation 1. TRANSFER CASE REMOVAL 2. remove front and rear drive shafts 3. remove the cotter pin, or remove the nut stacking and then unscrew the parking brake drum retaining nut. 4. pull the brake drum off the transfer output shaft, then remove parking brake plate assembly from the output shaft rear bearing retainer. 5. remove the speedometer cable from the rear bearing retainer 6. remove the rear bearing retainer and its gasket 7. remove the speedo drive gear and spacer from the transfer output shaft 8. remove the tranfser case cover assembly and gasket 9. remove the cotter pin and screw plug from the shift fork. 10. remove the locking plate and remove the shift fork shaft towards the rear with a drift,preferrably brass or aluminum, now remove the shift fork. 11. remove the shaft complete with high speed gear and the high and low clutch sleeve. next remove the low speed gear from the case. 12. next remove the output shaft out of the gear, you will need to press or drive it out, carefull not to damage. 13. remove the idle shaft from the casing. 14. remove the bearings,spacer and thrust washers, it is imprtant to take note of the order by which they are removed. 15. next remove the front part of the casing and gasket from the transmission. Transmision Removal 1. drain fluid from transmission. 2. remove gear shift boot and shift lever then remove top cover assembly from transmission. 3. detach all electrical leads from transmission. 4. next remove flywheel inspection cover 5. remove bolts attatching the transmission to the bell housing and carefully remove transmission. 6. installation of 5 speed transmission is reverse of removal. |
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