Tr6060 Manual Transmission (Service Information): Disassembly: Disassemble: Notes

Position the transmission over a suitable drain pan and empty the lubricant. Place the transmission on a stable work surface. If the bellhousing is attached to the transmission, remove the bellhousing.

1. Remove the bolts (2) holding the shift cover to the extension housing.
2. Separate the shift cover (1) from the extension housing.
   Fig 2: Offset Lever Roll Pin

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3. Using a suitable hammer and punch, remove the roll pin (2) holding the offset lever (1) to the shaft rail.
   Fig 3: Offset Lever

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4. Remove the offset lever (1) from the shift rail (2).
   Fig 4: Extension Housing Nuts

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5. Remove the nuts (2) holding the top of the extension housing (1) to the transmission.
   Fig 5: Extension Housing Bolts

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6. Remove the bolts (2) holding the extension housing (1) to the transmission.
   Fig 6: Removing/Installing Extension Housing

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7. Pry the extension housing (1) from the transmission (2) at the pry points.
   Fig 7: Clutch Release Bearing

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8. Remove the bolts holding the clutch release bearing to the transmission.
9. Separate the clutch release bearing from the transmission.
   Fig 8: Transmission Holding Fixture

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10. Remove all but two of the bolts holding the input shaft adapter housing to the transmission.
11. Place the tool (special tool #9387, Fixture, Transmission Holding) in position on the front of the transmission.
12. Install four bolts to hold the fixture to the bellhousing mount locations on the transmission.
    Fig 9: Bench Mount Transmission Holding Fixture

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13. Insert transmission fixture into the tool (special tool #9385, Holding Fixture, Bench Mount) that is bolted to a suitable work bench.
    Fig 10: Output Shaft & Packing Ring

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    NOTE:

    If the output shaft packing (1) is damaged, it does not require replacement. It can be discarded.

14. Remove the output shaft (2) packing (1).
    Fig 11: Roller Bearing Snap-Ring

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15. Remove the snap ring (1) holding the roller bearing (2) to the mainshaft.
    Fig 12: Roller Bearing & Spacers

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16. Remove the roller bearing (1) and spacers (2) from the mainshaft.
    Fig 13: Reverse Gear Snap Ring

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17. Remove the snap ring (2) holding the reverse gear on the mainshaft.
    Fig 14: Reverse Gear Thrust Washer

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18. Remove the reverse gear thrust washer (2) from the mainshaft.
    Fig 15: Reverse Gear

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19. Remove the reverse gear (1) from the mainshaft (2).
    Fig 16: Reverse Gear Bearing

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20. Remove the reverse gear bearing (1) from the mainshaft (2).
    Fig 17: Reverse Synchronizer Rings

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21. Remove the reverse synchronizer rings (1) from the reverse synchronizer hub.
    Fig 18: Reverse Synchronizer Snap Ring

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22. Remove the snap ring (2) holding the reverse synchronizer hub (1) on the mainshaft.
    Fig 19: Reverse Fork Snap Ring

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23. Remove the snap ring (2) holding the reverse shift fork on the shift rail (discard snap ring)  .
    NOTE:

    If necessary, the sleeve and detents can be removed separately from the mainshaft.

    Fig 20: Reverse Hub & Fork

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24. Remove the reverse shift fork (1), synchronizer hub, and sleeve (2) from the mainshaft as an assembly if possible.
    Fig 21: Reverse Countershaft Snap Ring

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25. Remove the snap ring (2) holding the reverse gear (1) on the countershaft.
    Fig 22: Reverse Countershaft Gear

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26. Using a typical three jaw puller (2) and (special tool #10027, Button, Press), pull the reverse gear (1) from countershaft.
    Fig 23: 5th Gear Snap Ring

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27. Remove the snap ring (1) holding the fifth gear thrust washer (2) on the countershaft.
    Fig 24: 5th Thrust Washer

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28. Remove the fifth gear thrust washer (1) from the countershaft (2).
    Fig 25: 5th Gear & Countershaft

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29. Remove fifth gear (1) from the countershaft (2).
    Fig 26: 5th Gear Bearing

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30. Remove the fifth gear bearing (1) from countershaft (2).
    Fig 27: 5th Gear Bearing Spacer

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31. Remove the fifth gear bearing spacer (1) from countershaft (2).
    Fig 28: 5th Gear Synchro Rings

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32. Remove the fifth gear synchronizer rings (1) from the 5-6 synchronizer hub (2).
    Fig 29: 5th Gear Retainer Ring

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33. Remove the retainer (1) holding the split ring on fifth gear and the mainshaft (2).
    Fig 30: Split Rings

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34. Remove the split rings (1) holding fifth gear on the mainshaft (2).
    Fig 31: 5th Gear Puller

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35. Using tools (special tool #9382, Bridge),(special tool #9378, Bolts, Puller), (special tool #10027, Button, Press) and (special tool #9379a, Remover, Gear), remove fifth gear (4) from the mainshaft.
    Fig 32: 5-6 Shift Fork Snap Ring

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36. Remove the snap ring (1) holding the 5-6 gear shift fork on the shift rail (2).
    Fig 33: 5-6 Hub Snap Ring

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37. Remove snap ring (1) holding the 5-6 synchronizer hub on the countershaft.
    Fig 34: 5-6 Fork & Sleeve

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38. While pulling or prying upward on the 5-6 shaft fork (1), remove the synchronizer sleeve (2), and detents (3) from the 5-6 synchronizer hub.
    Fig 35: 5-6 Hub Puller

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39. Using tools (special tool #9382, Bridge) (1), (special tool #9378, Bolts, Puller) (2),(special tool #10027, Button, Press) and (special tool #10026, Puller, Synchro Hub) (3), remove the 5-6 synchronizer hub from the countershaft.
    Fig 36: 6th Synchro Rings

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40. Remove the synchronizer rings (1) from sixth gear (2).
    Fig 37: 6th Gear & Countershaft

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41. Remove sixth gear (1) from the countershaft (2).
    Fig 38: 6th Gear Bearing

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42. Remove the sixth gear bearing (1) from the countershaft (2).
    Fig 39: 6th Gear Bearing Spacer

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43. Remove the sixth gear bearing spacer (1) from the countershaft (2).
    Fig 40: Top Cover

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44. Remove the bolts holding the top cover (1) to the transmission housing (2).
45. Separate the top cover (1) from the transmission (2).
    Fig 41: Side Detent

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46. Remove shift detent plug (1) from the right side of transmission (2).
    Fig 42: Skip Shift Solenoid

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47. Remove the skip shift solenoid (1) from the left side of transmission (2).
    Fig 43: Skip Shift Lever

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48. Using a suitable pin-punch, drive the roll pin downward until the skip shift lever (1) is free on the shift rail (2).
    Fig 44: Roller Detent Plug

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49. Remove plug (1) holding the roller detent in the transmission adapter (2).
    Fig 45: Detent & Spring

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50. Extract the roller detent (1) and spring (2) from the bore in the transmission adapter.
    Fig 46: Torx Screws

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51. Remove the shift lever guide bolts (2) from the top of transmission housing (1).
    Fig 47: Adapter Bolt Location

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52. Remove the remaining bolts (3) holding the input shaft adapter (2) to the transmission housing.
    Fig 48: Transmission Case

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53. Lift the transmission housing (1) upward and off of the input shaft adapter plate (2) and remove skip shift lever from shift rail.
    Fig 49: Removing/Installing Reverse Shaft Rail Assembly

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54. Remove reverse shift rail (2) assembly from input shaft adapter plate (3).
    Fig 50: Mainshaft, Shift Rail, Adapter Plate & Countershaft

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55. Tilt the countershaft (4) sideways, then remove the mainshaft (1) and the shift rail (2) from the adapter plate (3).
56. Remove the countershaft (4) assembly from the adapter plate.
    Fig 51: Input Shaft Synchro Rings

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57. Remove the input shaft synchronizer ring (1) and the input shaft (2) from transmission adapter.