Case

Disassembly

1. NOTE: Case disassembly is required to enable reuse of smaller parts.

   Using Impact Slide Hammer T50T-100-A and a suitable blind hole puller, remove the input shaft bearing outer race from the case (7005).

2. NOTE: The oil baffle will be destroyed when the race is removed. Discard the oil baffle and install a new one during assembly.

   NOTE: The through-bore of oil seal (7052) is designed such that oil seal can be removed without having to disassemble the transmission if removal and replacement of oil seal is all that is required. Tap on oil seal with a screwdriver until oil seal turns then use the screwdriver to pry out oil seal. Insert new oil seal and drive it in flush with the case. Driving the seal into the case itself is NOT recommended.

   Remove the oil baffle and input bearing front shims.

   
   
   
   
   

3. Remove the front bearing outer race with Impact Slide Hammer T50T-100-A and Internal Puller D80L-943-A.

   
   
   
   
   

4. If required, remove the case plugs (7A010), and sealing rings from the case.

   
   
   
   
   

5. If case replacement is required, remove the three shift rail detents from the case.

   
   
   
   
   

6. If required, remove the slotted spring pins that hold the 5th-reverse interlock plate from their bores in the case just below the shift control housing (7203).

   
   
   
   
   

7. If required, remove the central shift rail needle bearing from the case using Impact Slide Hammer T50T-100-A and Blind Hole Puller D80L-100-Q or equivalent.

   
   
   
   
   

Assembly

1. If they were removed, tap the 5th-reverse interlock plate roll pins into their bores in the case until the bigger one bottoms out (sticks out approximately 8mm (0.315 inch); the small one sticks out 4-5mm (0.158-0.197 inch). Do not allow it to bottom out.

   
   
   
   
   

2. Heat the case in the area of the bearing bore of 5th-reverse shift rail to 160°C (320°F) with Rotunda Heat Gun 107-R0300 or equivalent. Drive the bearing sleeve in with Needle Bearing Replacer T87T-7025-DH and Driver Handle T80T-4000-W until it is flush with the surface of the bore.

   
   
   
   
   

3. If removed, install the case plugs into the case. Tighten to 60 Nm (44 lb-ft). Both case plugs are of the straight-thread type, which require rubber sealing rings to prevent leakage. (These torque values apply to a cold case.)

4. Insert the three shift rail detent bolts into their respective bores in the case. They must seat in the detents in their respective shift rails and must move freely when in their installed positions.

   
   
   
   
   

5. Place a new shifter shaft seal on the release bearing guide tube (7.3L and 7.5L housings only).

6.  CAUTION: If the countershaft cluster gear (7113), input shaft (7017), mainshaft or one or more tapered roller bearings has been replaced, it is mandatory that the tapered roller bearings be adjusted to obtain a preload of 0.02 to 0.11mm (0.00079 to 0.00434 inch). Refer to Adjustments in this section for procedure.

   Position the oil seal in the case. Using Driver Handle T80T-4000-W and Front Seal Replacer T87T-7025-EH, drive in the oil seal until it seats against its stop.

   
   
   
   
   

7. Heat up the mounting bore in the case for the outer race of the output shaft bearing (7065) to 160°C (320°F) with Rotunda Heat Gun 107-R0300 or equivalent.

8. Position the output bearing front shim with proper thickness in the bore. Using Driver Handle T80T-4000-W and Bearing Cup Replacer T73T-4222-A, drive the output shaft bearing in until it seats against the stop in the case.

   
   
   
   
   

9. Heat the case in the area of the bearing (7025) of input shaft to 160°C (320°F) with Rotunda Heat Gun 107-R0300 or equivalent.

10. Position the correct input bearing front shim in the bore for the bearing. Using Driver Handle T80T-4000-W and Mainshaft Front Bearing Cup Replacer T87T-7025-PH, drive the bearing in until it seats against its stop in the bore.