For 1990-2009 cars

### Extension Housing Removal

#### Tools Required

• | J 3289-20 Holding Fixture

• | J 44395 Transmission Holding Fixture

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Remove the transmission from the vehicle. Refer to Transmission Replacement .
2. Remove the concentric actuator from the transmission. Refer to Clutch Concentric Actuator Cylinder Replacement .
3. Remove the clutch housing to transmission retaining bolts (1).
4. Remove the clutch housing from the transmission.
5. Install the J 44395 (3).
6. Install the J 44395 to transmission retaining bolts (2) and tighten until firm.
7. Mount the transmission on a workbench using the J 3289-20 (1).
8. Rotate the transmission into a horizontal position.
9. Remove the transmission drain plug and drain the transmission fluid.
10. Shift the transmission into NEUTRAL (N).
11. Remove the transmission vent tube to transmission case retaining bolt (1).
12. Remove the transmission vent tube from the vent pipe.
13. Disconnect the reverse lockout solenoid electrical connector (3).

Important: DO NOT damage the reverse lockout solenoid electrical connector (3).

14. Remove the reverse lockout solenoid to transmission extension housing retaining screw (2).
15. Remove the reverse lockout solenoid (1) from the transmission extension housing.
16. Remove the shifter cover plate to transmission retaining bolts (2).
17. Remove the shifter cover plate (1) from the transmission (3).
18. Install the J 45012 (3) to the drive flange (2).
19. Install the J 45012 to drive flange retaining bolts (4) and nuts (1) and tighten until firm.
20. While holding the J 45012 (5), remove the flange retaining nut (2) using the J 29873 (1) from the flange (4).

Discard the nut.

21. Remove the drive flange thrust washer (3).
22. Remove the J 45012 to drive flange retaining bolts (4) and nuts (1).
23. Remove the J 45012 (3) from the drive flange (2).
24. Install the J 45019 (2) to the drive flange (4).

Remove the drive flange (1) using the J 45019 J 45019 (2).

25. Install the J 45019 to drive flange retaining bolts (1), spacers (3) and nuts (5) and tighten until firm.
26. Remove the drive flange (4) using the J 45019 J 45019 (2).
27. Remove the rear extension housing to transmission case retaining bolts (1).
28. Remove the rear extension housing (2).

### Reverse Speed Gear Removal

1. Roll the shift guide rollpins (3).
2. Remove the shift guide (2).
3. Remove the shift shaft extension (1).
4. Remove the mainshaft snap ring (1) from the mainshaft (5).
5. Remove the mainshaft spacer (2) from the mainshaft (5).
6. Remove the mainshaft rear roller bearing (3) from the mainshaft (5).
7. Remove the mainshaft spacer (4) from the mainshaft (5).
8. Remove the mainshaft snap ring (1) from the mainshaft (7).
9. Remove the reverse gear thrust washer (2) from the mainshaft (7).
10. Remove the reverse gear (3) from the mainshaft (7).
11. Remove the reverse gear caged needle bearing (4) from the mainshaft (7).
12. Remove the wave washer (5) from the mainshaft (7).
13. Remove the reverse gear synchronizer blocking ring (6) from the mainshaft (7).

### Reverse Shift Fork Removal

1. Remove the reverse synchronizer retainer ring (1).
2. Remove the reverse shift fork to shift rail snap ring (1) .
3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
4. Remove the following parts in order:

4.1. | The thrust washer (1)

4.2. | The reverse synchronizer assembly (2) and the shift fork (3)

### 5th/6th Speed Driven Gear Removal

#### Tools Required

• | J 8433 Universal Bridge Puller

• | J 39431 Gear Remover and Bolts

Remove the 5th/6th speed driven gear (4) from the mainshaft. Use the J 8433 (1), the J 39431 (2) and the J 39431 (3).

### Countershaft Gear Removal

#### Tools Required

J 25031-A Three Jaw Puller

1. Remove the reverse shift shaft pin (1) and collar (2).
2. Remove the countershaft retainer clip (1).
3. Attach the J 8433 (2) , the J 39431 (3) and the J 39431-4 (1).
4. Remove the countershaft gear (1).
5. Remove the countershaft retainer (1) and spacer (2).
6. Remove the 5th gear (1) from the countershaft (2).
7. Remove the needle bearing (1) from the countershaft (2).
8. Remove the 5th/6th speed shift fork retainer ring (1).
9. Remove the spacer (1) from the countershaft (2).
10. Remove the retainer clip (1) from the countershaft (2).
11. Remove the 5th/6th shift fork (6), synchronizer sleeve (5), speed drive gear synchronizer blocking ring (4), speed drive gear friction cone (3), speed drive gear inner cone (2), speed drive gear thrust washer (1).
12. Install the J 25031-A (1) to the synchronizer hub assembly (2).
13. Remove the synchronizer hub assembly (1).
14. Remove the 5th/6th speed drive gear synchronizer blocking ring (1), speed drive gear friction cone (2), speed drive gear inner cone (3) and speed drive gear thrust washer (4).
15. Remove the 6th drive gear (1), caged needle bearing (2), and spacer (3) from the countershaft (4).

### Transmission Case Removal

1. Remove the shift detent assembly (1).
2. Remove the shift detent plug (1), spring (2) and ball (3).
3. Remove 9 of the 11 adapter plate to transmission case bolts (1).
4. Rotate the transmission into the vertical position.
5. Remove the last 2 adapter plate to transmission case bolts (2).
6. Remove the shift lever guide bolts (1).
7. Remove the magnets (1) from the transmission case (2).
8. Remove the transmission case and the offset lever together as follows:

8.1. | Slide the transmission case (1) up and off of the gear clusters and the shift shaft components.

8.2. | Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.

8.3. | Remove the offset lever from the transmission case.

### Guide Plate Removal

1. Remove the detent guide plate retaining bolts (1).
2. Remove the detent guide plate (2).

### Reverse Lockout Assembly Disassemble

Caution: Refer to General Repair Instructions in the Preface section.

1. Remove the O-ring (1) from the body (8).
2. Remove the retainer ring (2) from the body (8).
3. Remove the reverse lockout inner spring (7).
4. Compress the reverse lockout plunger (3) and the collar (5) in a vise and remove the retainer ring (6).
5. Remove the reverse lockout plunger (3).
6. Remove the reverse lockout outer spring (4).
7. Remove the reverse lockout collar (5).

### Shift Shaft Assemblies and Gear Cluster Removal

1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
2. Remove the 5th/6th and the reverse shift shaft assembly (1) from the adapter plate (2).
3. Remove the countershaft (1) from the adapter plate (3). Lift up the mainshaft (2) enough in order to remove the countershaft (1).
4. Remove the mainshaft and the shift shaft components as an assembly (1) from the adapter plate.

Important: When removing the shift shaft be careful not to lose the dowel pin.

5. Remove the shift shaft assembly from the mainshaft.
6. Remove the input shaft (1) from the adapter plate (2).