T5

IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor
vehicles as well as the personal safety of the individual doing the work. This Manual provides general directions for
accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill
of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish
that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
NOTES, CAUTIONS, AND WARNINGS

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there
for a specific purpose. NOTES give you added information that will help you to complete a particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you
to be especially careful in those areas where carelessness can cause personal injury. The following list contains some
general WARNINGS that you should follow when you work on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up.
• Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
• Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless
instructed otherwise for a specific operation. If you have a manual transmission, it should be in REVERSE (engine
OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4" x 4"
or larger) to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
• Keep yourself and your clothing away from the moving parts, when the engine is running, especially the fan and
drive belts.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.
• Do not smoke while working on the vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work
on a vehicle. Tie long hair securely behind the head.
• Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to operate at any time
by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore, care should
be taken to ensure that the electric cooling fan is completely disconnected when working under the hood.
• Disconnect the negative battery ground cable before using any electric welding equipment.
Contents
Section Page
1 INTRODUCTION AND DESCRIPTION
1-1. Introduction 1-1
1-10. Description 1-1
2 T5 WC & NWC ON-VEHICLE SERVICE AND TROUBLESHOOTING
2-1. Maintenance 2-1
2-7. Troubleshooting 2-1
2-10. Transmission Removal 2-4
2-21. Transmission Installation 2-7
3 T5 WC DISASSEMBLY
3-1. General Information 3-1
3-6. T5 WC Transmission Disassembly Procedures 3-1
4 T5 NWC DISASSEMBLY
4-6. T5 NWC Transmission Disassembly Procedures 4-1
5 T5 WC & NWC CLEANING, INSPECTION, REPAIR OR REPLACEMENT
5-1. Cleaning 5-1
5-5. Inspection 5-8
5-10. Repair or Replacement 5-16
6 T5 WC ASSEMBLY
6-4. T5 WC Transmission Assembly Procedures 6-1
7 T5 NWC ASSEMBLY
7-4. T5 NWC Transmission Assembly Procedures 7-1
Section 1
Introduction and Description
1-1. INTRODUCTION 1-7. The exploded view illustrations in Section 5 (figure 5-
1. or 5-2) make it possible to view the complete transmis-
1-2. PURPOSE. This manual contains maintenance, sion assembly in addition to the illustrations in the
service and parts information for the T5 Five-Speed Sections 3,4,6 and 7 relating to a specific disassembly or
Manual Transmission. assembly procedure.
1-3. SCOPE. As you will see in the Table of Contents, this 1-8. PART NUMBERS. The purpose of the index
manual provides information for maintenance, trouble- numbers in the illustrations in this manual is to identify
shooting, disassembly, cleaning, inspection, repair or parts. Part numbers are not used. Once a part is identified,
replacement, and assembly of the transmission. refer to the T5 Transmission Parts Catalog for the correct
part number.
1-4. TS TRANSMISSION CLASSES. Two basic T5
transmission classes are covered in this manual: WC 1-9. ABBREVIATIONS. Abbreviations, other than those
(world class) and NWC (non-world class). Separate in common use, found in this manual are identified in
disassembly (Sections 3 and 4) and assembly (Sections 6 Table 1-1.
and 7) instructions are provided for each of these classes. 1-10. DESCRIPTION
In other sections of the manual, variations within the
classes are noted in the instructions and illustrations. 1-11. TRANSMISSION DESCRIPTION. The T5 is a
NOTE five speed, countershaft, helical gear transmission. It is
fully synchronized for ease of shifting. Gear ratios vary
The parts shown in the illustrations in the service from model to model (refer to vehicle service manual for
instructions are typical for those used in a particu- specifications). The input and output ends of the input and
lar class of transmission (WC or NWC). Some output shafts are supported by tapered roller bearings. A
parts may be encountered in service that are pilot roller bearing is used between the input and output
different in appearance than those illustrated. shafts. The countershaft gear is supported in tapered roller
These "different" parts perform the same function bearings for WC models and straight roller bearings for
as those illustrated. NWC models. These and other basic differences in the two
classes are shown in Table 1-2.
1-5. T5 TRANSMISSION CLASS IDENTIFICATION.
The T5 transmission can be identified as WC or NWC by 1-12. APPLICATION. The T5 transmission is used on
the last three digits of the transmission part number (see sports cars, small to medium sedans and coupes, compact
Table 3-1 or 4-1 in the disassembly sections). In this trucks and vans, utility vehicles and similar 2-wheel and
manual, figure titles, lists, tables and main paragraph 4-wheel drive vehicles.
headings are identified as WC or NWC. When using the
manual, make sure you are in the proper section for the Table 1-1. Abbreviations
transmission being serviced. AR As Required
1-6. PART IDENTIFICATION. Each detail part shown Assy Assembly
in the exploded views in this manual/or a particular ID Inside Diameter
NP Not Procurable
transmission class (WC or NWC) is assigned an index OD Outside Diameter
number. This same index number is used to identify the PN Part Number
part throughout this manual. For example, WC index QTY Quantity
number 116 (in parentheses in the text) refers to the TiK Total Indicator Reading
countershaft gear in all applicable sections. The same is
true for NWC index number 105.
Table 1-2. Basic Differences Between T5 WC and NWC Classes

DESC RIPTION
FEATURE
WC NWC
Bearings under gears Needle bearings Journals
Blocking rings Fiber synchronizers Brass synchronizers
Countershaft bearings Tapered roller bearings Straight roller bearings
1-1
Section 2
T5 WC & NWC On-Vehicle Service and Troubleshooting
2-1. MAINTENANCE 2-6. CHANGING LUBRICANT. Proceed as follows (see
figure 2-2):
2-2. GENERAL. The only periodic maintenance required
a. Wipe drain and fill plugs (1 and 2) and surrounding
for the T5 transmission is to maintain proper lubrication.
areas clean.
2-3. LUBRICATION SCHEDULE. Refer to the Vehicle b. Place suitable container under transmission.
Owner's Manual or Service Manual. c. Remove drain plug (1).
d. Remove fill plug (2).
CAUTION e. Allow all lubricant to drain.
Excessive temperatures may break down the f. Install drain plug (1) and torque to 20 lb-ft (27 Nm).
transmission lubricant (refer to vehicle service g. Add lubricant through fill plug opening until lubricant
manual for maximum allowable temperature). If just begins to drip back out of opening.
there is reason to believe that the transmission has
been subjected to temperatures exceeding 275° F, NOTE
change the lubricant immediately. The amount of lubricant required varies from
model to model. Refer to the vehicle service
2-4. APPROVED LUBRICANT. MostT5 transmission manual for transmission capacity.
models use Dexron® n automatic transmission fluid.
Refer to the vehicle owner's manual or service manual for h. Install fill plug and torque to 20 lb-ft (27 Nm).
lubricant specifications.
2-7. TROUBLESHOOTING
CAUTION
Do not mix different brands or types of transmis- 2-8. GENERAL. In the event of operating difficulty, it is
sion lubricant DO NOT USE GEAR OIL IN THE recommended that the transmission (engine) be shut
T5 TRANSMISSION SINCE THIS MAY DAMAGE down. In most cases, to accurately pinpoint the source of.
THE BLOCKING RING MATERIAL. trouble, it may be necessary to remove and disassemble, or
partially disassemble, the transmission. Specific inspection
2-5. CHECKING LUBRICANT LEVEL. Proceed as procedures for detail parts of the transmission are pro-
follows (see figure 2-2): vided in Section 5.
NOTE 2-9. TROUBLESHOOTING CHART. Table 2-1 lists
To check or drain the lubricant, the transmission troubles which may be encountered along with possible
should be warm. This is best done shortly after causes and remedies.
engine shutdown.
a. Wipe fill plug (2) and surrounding area clean.
b. Remove fill plug (2).
c. When transmission is full, lubricant will just drip out
fill plug opening.
d. Add approved lubricant if required.
e. Install fill plug (2) and torque to 20 lb-ft (27 Nm).
2-1
Table 2-1. Troubleshooting Chart
PROBLEM POSSIBLE CAUSE REMEDY
Will not shift Control lever assy broken or damaged Replace control lever and housing assy
(control lever
moves) Damaged offset lever, shift fork, selector Remove extension or adapter and case
plate or selector arm cover. Check for damagea parts. Replace
damaged parts
Hard shift or con- Clutch not releasing Adjust or replace clutch
trol lever will not
move into gear Improper or low transmission lubricant Add or drain and replace with proper
lubricant (refer to paragraph 2-4)
Shifter shaft or shift rail binding Remove extension or adapter and case
cover. Check for damagea parts. Replace
damaged parts
Binding of sliding synchronizers or gears Remove extension or adapter and case
cover. Reach down into transmission and
check that synchronizers and gears (parts
with shifting grooves) slide freely on shafts.
Remove and replace damaged parts
If reverse only, seized backup switch Remove and check backup switch.
Replace if seized
Worn or damaged flywheel pilot bushing Replace pilot bushing
Bell housing misaligned Align bell housing to within 0.010 inch
TIR on face and in bore
Gears clash when Engine idle speed too high Adjust idle speed to specifications
shifting
Clutch damaged or out of adjustment Adjust or replace clutch
Pilot bearing between input shaft and Disassemble and check bearing rollers,
output shaft binding input shaft ID and output shaft OD.
Replace damaged parts
Damaged synchronizer Disassemble and check for damaged
synchronizer parts. Replace damaged
parts
Bell housing misaligned Align bell housing to within 0.010 inch
TIR on face and in bore
Damaged gear or gears Disassemble and check for gear damage.
Replace damaged gears
Worn or damaged flywheel pilot bushing Replace pilot bushing
Transmission Loose transmission or flywheel housing Torque bolts to specifications. Realign if
jumps out of gear bolts, improper alignment necessary
Synchronizer damaged or excessively worn Disassemble and check for worn or
damaged synchronizer parts. Replace
damaged parts
Blocking ring damaged, worn index slots Disassemble and check blocking ring for
or friction surfaces worn or damaged wear or damage. Replace worn or
damaged parts
Excessive countershaft end play Disassemble and check. Replace worn or
damaged parts. Reshim if roller bearings
used.
Shifting fork loose on shaft or rail; worn Disassemble and check for wear or
or damaged fork or inserts damage. Replace worn or damaged parts
2-2
Table 2-1. troubleshooting Chart (Cont)
PROBLEM POSSIBLE CAUSE REMEDY
Transmission Fork or offset lever loose on shaft or rail Remove extension or adapter and case
locked in one gear cover. Check for loose parts on shifter
shaft or rail. Replace roll pin(s). If still
loose, replaced shaft or rail and/or
attached parts as required
Worn or damaged forks, offset lever, Remove extension or adapter and case
shaft or rail cover. Check for wear or damage
Replace damaged parts
Worn or damaged synchronizer Disassemble and check for worn or
damaged synchronizer parts. Replace
worn or damaged parts
Worn or damaged gears Disassemble and check for worn or
damaged gears. Replace worn or
damaged gears
Transmission Improper or low transmission lubricant Add or drain and replace with proper
noise NOTE: lubricant (refer to paragraph 2-4)
Make sure noise
is coming from Loose bolts or other attaching parts Make sure all attaching parts are torqued
transmission and to specifications
not clutch release Improper flywheel housing to engine Check alignment and correct if neces-
bearing or other crankshaft alignment sary per vehicle service manual
components.
Disassemble and check bearings, bear-
ing rollers and parts in and on which
Noisy transmission bearings they operate for wear or damage
Replace worn or damaged parts
Disassemble and check for worn or
damaged gears (including speedometer
Noisy gears gear). Replace worn or damaged gears
Transmission Leakage from other components Verify transmission leakage Thoroughly
leakage clean all exposed surfaces, then check
for leaks
Vent or breather clogged Remove vent or breather and clean or
replace
Too much or improper lubricant Remove fill plug to check for excess, or
drain and replace
Loose bolts at sealing faces Torque bolts to specifications
Improperly applied sealant Separate and thoroughly clean leaking
surfaces. Reapply sealant. Replace parts
and torque bolts to specifications
Worn or damaged oil seal Replace oil seal
2-3
2-10. TRANSMISSION REMOVAL
2-11. GENERAL. The following paragraphs provide
procedures for removing the T5 transmission. For 4-
wheel drive vehicles, instructions are also given for
removing the transfer case. If the vehicle is not
equipped with 4-wheel drive, disregard paragraph 2-18
and references to the transfer case in the other
paragraphs.
2-12. OTHER COMPONENTS. Before or during
transmission removal, it may be necessary to remove
or disconnect other components, this is required to
provide access to or clearance for the transmission
(and transfer case, if used). Since these components
vary widely from vehicle to vehicle, specific instruc-
tions are not provided in this manual. Refer to the vehi-
cle service manual. Such components may include:
a. Console or similar cover.
b. Parking brake lever and controls.
c. Wiring and/or vacuum harness.
d. Exhaust system components.
e. Clutch components.
f. A skid plate or protective covers on the underside
of the vehicle
2-13. SUPPORTING TRANSMISSION (OR TRANS-
FER CASE, IF USED). Before removing any parts
which attach or support the transmission (and trans-
fer case, if used), support the transmission on a suit-
able jack or stand. The jack or stand must be capable
of supporting and holding the transmission indepen-
dently. Also the jack or stand shall be capable of lower-
ing, raising and moving the transmission laterally.
2-14. PROCEDURES WITH VEHICLE ON
FLOOR. Before raising the vehicle, proceed as follows:
a. Position vehicle over suitable hoist.
WARNING
When using a drive-on lift, be sure to properly
chock the wheels to prevent the vehicle from roll-
ing off.
b. Disconnect negative battery terminal.
c Shift vehicle into neutral and release parking
brake. On 4-wheel drive vehicles, shift into 4HI.
d. Remove shift lever (see figure 2-1):
1. Detach bottom of boot (1) so that it can be Figure 2-1. Shift Lever
raised to provide access to lower end of shift lever. Boot
attachment methods may vary from that shown.
2. If shift lever is threaded on, loosen lock nut (2),
then remove shift lever (4) using wrench on flats (5) 2-16. DRAINING LUBRICANT. Drain lubricant
provided. from transmission (and transfer case, if used) (refer to
3. If shift lever is attached with screws (3), then paragraph 2-6, steps a through e). Reinstall fill and
remove screws (3) and shift lever (4). drain plugs.
2-15. LIFTING VEHICLE. Lift vehicle on suitable 2-17. REMOVING REAR PROPELLER SHAFT.
hoist, allowing clearance for removal of transmission The rear propeller shaft (3, figure 2-2) is splined to the
(and transfer case, if used), and related components transmission (or transfer case, if used) output shaft.
such as propeller shaft (or shafts), cross members and It will be necessary to disconnect the rear end of the
supports. It unsure, refer to vehicle service manual for propeller shaft first, then move the shaft rearward to
approved lift points. disengage the splines. Support the propeller shaft to
prevent it from dropping. Bend universal joints just
NOTE enough to permit shaft removal. Otherwise damage
On some vehicles, it may be necessary to remove may result. Refer to the vehicle service manual foi
or disconnect other components (refer to para- specific procedures.
graph 2-12).
2-4
1. DRAIN PLUG
2. FILL PLUG 8. BOLT
3. PROPELLER SHAFT 9. LOCK WASHER
4. CLUTCH HOUSING 10. TRANSMISSION
5. TRANSMISSION 11. BOLT
MOUNT 12. NUT
6. CROSS MEMBER 13. WASHER
7. BACK-UP SWITCH 21. OIL SEAL
Figure 2-2. Transmission

2-18. REMOVING TRANSFER CASE (4-WHEEL 2-20. REMOVING TRANSMISSION. Proceed as
DRIVE VEHICLES ONLY). On 4-wheeI drive vehi- follows (see figure 2-2 and refer to warning following
cles, proceed as follows to remove transfer case (see paragraph 2-14, step a):
figure 2-3 and 2-4 and refer to WARNING following
paragraph 2-14, step a): a. Support transmission on suitable jack or stand
(refer to paragraph 2-13).
a. Remove front propeller shaft (17, figure 2-3) by b. Remove back-up switch electrical connection (7).
removing bolts (15) and retainers (16). Observe same Also, if used, remove neutral switch electrical connec-
precautions in handling front propeller shaft as for tor or any others that may be used.
rear propeller shaft (refer to paragraph 2-17). c. Remove speed sensor electrical harness or
b. Remove shift lever linkage and bracket attached speedometer cable (location may vary).
to transfer case and transmission. d. Remove bolts (8) and lockwashers (9) attaching
c Support transfer case on suitable jack or stand transmission (10) to transmission mount (5).
(refer to paragraph 2-13). e. Remove cross member (6).
CAUTION CAUTION
Make sure transfer case is completely supported Make sure transmission is completely supported
by jack or stand before removing bolts (18, figure by jack or stand before removing bolts (11)
2-4) attaching transfer case to transmission. Do attaching transmission (10) to clutch housing (4).
not allow transfer case to "hang" from transmis- Do not allow transmission to "hang" from
sion by splined shaft since this may damage clutch by splined shaft since this may damage
input bearings. input bearings.
d. Remove bolts (18) attaching transfer case (19) to f. Remove bolts (11) attaching transmission (10) to
transmission (10). clutch housing (4).
e. Move transfer case (19) straight back toward rear g. Using care not to dislodge clutch parts, move
of vehicle to completely disengage splines from trans- transmission (10) straight back toward rear of vehicle
mission (10). Remove gasket (20). to completely disengage splines from clutch.
f. Carefully lower transfer case on jack or stand. h. Carefully lower transmission (10) on jack or
2-19. REMOVING TRANSMISSION SUPPORT stand.
BRACES. The main transmission attachment points
are at the clutch housing (4, figure 2-2) and at the
transmission mount (5) on the cross member (6). Sup-
plemental support braces may or may not be used,
depending on the vehicle. If used, remove supplemen-
tal support braces and any other components neces-
sary to provide for transmission clearance.
10. TRANSMISSION
18. BOLT
19. TRANSFER CASE
15. BOLT 17. FRONT PROPELLER SHAFT
20. GASKET
16. RETAINER 19. TRANSFER CASE T5150 T5151
Figure 2-3. Front Propeller Shaft Figure 2-4. Transfer Case
2-6
2-21. TRANSMISSION INSTALLATION f. Remove jack or stand supporting transmission.
2-22. GENERAL. Install transmission (and transfer g. Install speed sensor electrical harness or
case, if used) in vehicle from which it was removed as speedometer cable (location may vary).
described in the following paragraphs. Note the h. Install back-up switch electrical connection (7)
following: and any other electrical connectors that were removed.
i. Install any supplemental supports or braces that
CAUTION were removed during transmission removal.
T5 transmissions are not necessarily inter-
changeable from vehicle to vehicle. Installation WARNING
of the transmission in a vehicle other than that Be sure to fill transmission with proper fluid
from which it was removed may result in prema- (refer to paragraph 2-4). Otherwise transmission
ture failure. will be damaged when engine is started. If vehi-
cle is driven, transmission could lock up causing
a. The following paragraphs provide procedures for personal injury.
installing the T5 transmission. For 4-wheel drive vehi-
cles, instructions are also given for installing the 2-24. INSTALLING TRANSFER CASE (4-WHEEL
transfer case. If the vehicle is not equipped with DRIVE VEHICLES ONLY). On 4-wheel drive vehi-
4-wheel drive, disregard paragraph 2-24 and references cles, proceed as follows to install transfer case (see
to the transfer case in the other paragraphs. figure 2-3 and 2-4):
b. Before or during removal of the transmission, a. Apply thin coat of high temperature grease to
arts not specifically related to the transmission may
E ave been removed to provide access or clearance. Be
sure to reinstall these components exactly as they
output shaft spline on transmission (10, figure 2-4).
b. Install new gasket (20) on transfer case (19)
mounting face.
were prior to removal (refer to paragraph 2-12). c. Raise transfer case (19) on jack or stand. Align
c. The transmission (and transfer case, if used) transfer case with transmission (10).
must be supported on a suitable jack or stand capa-
ble of raising it the transmission into position, align- CAUTION
ing and moving it to engage the drive splines. Make sure transfer case is in exact alignment
with transmission before engaging splines. Do
2-23. INSTALLING TRANSMISSION. Proceed as not force transfer case onto transmission. Other-
follows (see figure 2-2): wise damage may result. If necessary, turn
a. Apply thin coat of high temperature grease to transfer case output shaft to align input shaft
input shaft spline on transmission (10). spline with that on transmission.
b. Shift transmission (10) into high gear and raise d. Carefully move transfer case (19) forward, engag-
on jack or stand. Align transmission with clutch ing splines on transmission, until transfer case mount-
housing (4). ing flange contacts transmission (10).
CAUTION CAUTION
Make sure transmission is in exact alignment Keep transfer case completely supported by jack
with clutch before engaging splines. Do not force or stand until bolts (18) attaching transfer case
transmission input shaft into clutch. Otherwise (19) to transmission (10) are installed and tor-
damage may result. If necessary, turn trans- qued. Do not allow transmission to "hang" from
mission output shaft to align input shaft spline clutch by splined shaft since this may damage
with that in clutch. input bearings.
c. Carefully move transmission (10) forward, engag- e. Make sure mounting holes in transmission (10)
ing splines in clutch, until transmission mounting and transfer case (19) are aligned and install bolts (18).
flange contacts clutch housing (4). Torque bolts to 23 lb-ft (31 Nm). Remove jack or stand.
CAUTION f. Attach shift lever bracket and linkage removed
at transfer case removal
Keep transmission completely supported by jack g. Make sure front propeller shaft (17, figure 2-3)
or stand until bolts (11) attaching transmission is properly lubricated and install. Attach to transfer
(10) to clutch housing (4) are installed and tor- case (19) with retainer (16) and bolts (15). Torque bolts
qued. Do not allow transmission to "hang" from to 15 lb-ft (20 Nm).
clutch by splined shaft since this may damage
input bearings. WARNING
Be sure to fill transfer case with proper fluid
d. Make sure mounting holes in transmission (10) (refer to vehicle service manual). Otherwise
and clutch housing (4) are aligned and install bolts (11). transfer case will be damaged when engine is
Torque bolts to 55 lb-ft (75 Nm). Do not remove jack started. If vehicle is driven, transfer case could
or stand at this time lock up causing personal injury.
e. Install cross member (6). Install bolts (8) and
lpckwashers (9) attaching transmission (10) to trans-
mission mount (5). Torque bolts to 35 lb-ft (50 Nm).
2-7
2-25. INSTALLING REAR PROPELLER SHAFT.
Proceed as follows (see figure 2-2):
a. Make sure rear propeller shaft (3) is properly
lubricated.
b. Apply thin coat of high temperature grease to
output shaft spline on transmission (10) (or transfer
case, if used).
c. CarefuDy insert front end of rear propeller shaft
(3) into transmission (10) (or transfer case, if used). Use
care not to damage oil seal (21).
d. Connect rear end of rear propeller shaft at
differential (refer to vehicle service manual for specific
instructions).
2-26. FILLING TRANSMISSION WITH LUBRI-
CANT. Fill transmission (and transfer case, if used)
with proper lubricant refer to paragraph 2-6, steps
f through h).
2-27. COMPLETION OF INSTALLATION.
a. Lower vehicle to floor.
b. Install shift lever (see figure 2-1):
1. If shift lever is attached with screws, align
screw holes in shift lever (4) and transmission control
lever and install screws.
2. If shift lever is threaded on, screw shift lever
(4) onto transmission control lever. Hold in desire posi-
tion with wrench across flats (5) and tighten nut (2)
up against shift lever (4) to 34 lb-ft (47 Nm).
3. Reattach bottom of boot (1).
c. Connect negative battery terminal.
2-8
Section 3
T5 WC Disassembly
3-1. GENERAL INFORMATION 3-6. T5 WC TRANSMISSION DISASSEMBLY

3-2. This section provides disassembly instructions PROCEDURES
for the T5 WC transmission. The transmission class 3-7. REMOVAL OF T5 WC CONTROL LEVER
can be identified by the last three digits of the trans- AND HOUSING ASSEMBLY AND EXTERNAL
mission part number. WC units are listed in Table 3-1. COMPONENTS. Clean transmission exterior if neces-
If the number for the transmission to be disassembled sary, support on suitable holding fixture and proceed
is not listed in Table 3-1, refer to Section 4, T5 NWC as follows (see figure 3-1):
Disassembly.
a. Remove fill and drain plugs (1) and drain all fluid
3-3. During disassembly, refer to the illustrations from transmission.
provided with the text. In addition, an exploded b. Shift transmission into neutral at 3-4 position.
view of the complete assembly can be seen on figure
5-1 in Section 5, Cleaning, Inspection, Repair or CAUTION
Replacement. Failure to shift transmission into neutral at 3-4
position before removing control lever and hous-
3-4. This section provides instructions for complete ing assembly may result in driving roll pin (15,
disassembly of the T5 WC transmission as would be figure 3-2) into detent guide plate (18) when pin
the case for overhaul. If the transmission is not due is removed (paragraph 3-8).
for overhaul, and repair affecting specific parts is
required, disassemble only to the extent necessary to c. Remove screws (2). If extended control lever and
gain access to these parts. Parts removed from the housing assembly (3C) is used, also remove screws
transmission as subassemblies or groups need not be (2A).
disassembled for repair unless they contain the d. If necessary, use suitable knife to break sealant
affected parts. Total disassembly is recommended to bond between control lever and housing assembly (3A,
ensure that all parts are absolutely clean. 3B or 3C) and extension (17A) or adapter (17B).
Remove control lever and housing assembly. Remove
3-5. REMOVAL AND INSTALLATION OF boot (4) only if replacement is required.
TRANSMISSION. Refer to paragraphs 2-10 and f. Remove vent and o-ring assembly (5A) or
2-21. breather (5B).
g. As used, remove neutral switch (6), pin (7), har-
ness retainer (8), screw (9), speedo adapter (10) roll pin
(11), speedo driving gear (12) oil seal (13) and o-ring
(14).
Table 3-1. T5 WC Transmissions

Three Digits of Part Number: 1352-000-XXX)
114 thru 116 155 167 thru 169 194 thru 200
126 162 174 thru 177 202 thru 205
134 165 184 207
141
3-1
1. PLUG 3C. CONTROL LEVER & 7. PIN 12. SPEEDO DRIVING
2. SCREW HOUSING ASSY 8. HARNESS GEAR
2A. SCREW 4. BOOT RETAINER 13. OIL SEAL
3A. CONTROL LEVER & 5A. VENT AND O-RING 9. ADAPTER SCREW 14. O-RING
HOUSING ASSY ASSY 10. SPEEDO ADAPTER 17A, EXTENSION ASSY
3B. CONTROL LEVER & 5B. BREATHER 11. ROLL PIN 17B. ADAPATER ASSY
HOUSING ASSY 6. SWITCH ASSY T,
Figure 3-1. T5 WC Control Lever Housing and External Components
3-2
3-8. REMOVAL OF T5 WC EXTENSION OR 3-9. REMOVAL OF T5 WC CASE COVER AND
ADAPTER. With offset lever accessible and in neu- DISASSEMBLY OF SHIFT FORKS. With transmis-
tral at 3-4 position (paragraph 3-7, step b), proceed as sion assembly upright, proceed as follows (see figure
follows (see figure 3-2): 3-3):
a. Using suitable drift, drive roll pin (15) into off- a. Remove bolts (26 and 27).
set lever (20) and out of engagement with shifter shaft b. If necessary, use suitable knife to break sealant
(29). Tap drift with hammer just until offset lever feels bond between case cover (38) and transmission case
free on shaft. (117). Move case cover and attached parts toward
b. Remove bolts (16). drain plug side of transmission approximately one
c. If necessary, use suitable knife to break sealant inch, then lift straight up.
bond between extension or adapter (17A or 17B) and c. Dive out pin (28).
transmission case (117). Pull extension or adapter d. Slide out shifter shaft (29), freeing shift forks (30
straight out from transmission case. Offset lever (20) and 31), selector arm assembly (33), interlock plate (34)
will slide off shifter shaft (29) with extension or and selector plates (35) from case cover (38).
adapter. e. Remove inserts (32) from shift forks (30 and 31).
d. Remove offset lever (20), damper sleeve (21), f. Remove o-ring (36) from case cover (38) but not
spring (23), ball (22) and oil seal (24) from extension plug (37).
(17A) or adapter (17B). Remove roll pin (15) if loose or
drive out of offset lever (20) if still partially installed.
Do not remove detent guide plate (18) or plug (19).
a Remove oiling funnel (25).
15. ROLL PIN 23. SPRING

16. BOLT 24. OIL SEAL
17A. EXTENSION ASSY 25. OILING FUNNEL
17B. ADAPTER ASSY 29. SHIFTER SHAFT
18. DETENT GUIDE 117. CASE ASSY
PLATE
19. PLUG
20. OFFSET LEVER
2 1 . DAMPER SLEEVE
22. BALL T511B
Figure 3-2. T5 WC Extension or Adapter
3-3
3-10. REMOVAL OF T5WC5-R SHIFT LEVER (see
figure 3-4):
a. From inside transmission assembly, remove
retaining ring (39).
b. From outside transmission, remove pivot pin (40)
and back-up switch (41).
c. Work 5-R shift lever (42) out of engagement and
lift out top of transmission case (117).
3-11. REMOVAL OF T5 WC 5TH SYNCHRO-
NIZER, SHIFT FORK AND GEAR. At rear of trans-
mission case (117), remove parts as follows (see figure
3-5):
a. Remove snap ring (43) and 5th synchronizer
retainer (44).
b. Simultaneously pull 5th synchronizer assembly
(45) and 5th shift fork (51) with attached shift rail
assembly (53).
c To separate 5th shift fork (51) and shift rail
assembly (53), drive out roll pin (50). Remove inserts
(52) from fork.
Figure 3-3. T5 WC Case Cover
Figure 3-4. T5 WC 5-R Shift Lever
3-4
d. Refer to paragraph 3-19 for disassembly of 5th
synchronizer assembly.
e. Remove blocking ring (54) and 5th speed drive
gear (55) from transmission.
3-12. REMOVAL OF T5 WC SPEEDOMETER
GEAR. On models so equipped, remove speedometer
gear as follows: (see figure 3-6):
a. Remove one snap ring (56) from output shaft
(101).
b. Disengage clip (58) and remove speedometer gear
(57) and clip.
43. SNAP RING 52. INSERT

44. SYNC RETAINER 53. SHIFT RAIL ASSY
45. 5TH SYNCHRO- 54. BLOCKING RING
NIZER ASSY 55. 5TH SPEED DRIVE
50. ROLL PIN GEAR
51. 5TH SHIFT FORK 117. CASE ASSY
Figure 3-6. T5 WC Speedometer Gear
Figure 3-5. T5 WC 5th Synchronizer,
Shift Fork and Gear
3-13. REMOVAL OF T5 WC INPUT SHAFT. Make e. Rotate input shaft (65) to align flat on its clutch
alignment mark on input bearing retainer (60) and tooth ring with countershaft (116) and remove from
transmission case (117) and proceed as follows (see transmission.
figure 3-7): f. If necessary, remove bearing cone (64) from input
a. Remove bolts (59). shaft (65) using suitable puller.
b. If necessary, use suitable knife to break sealant g. Remove pilot bearing between input shaft (65)
bond between input bearing retainer (60) and trans- and output shaft (101) as follows, depending on bear-
mission case (117). Pull bearing retainer straight out. ing type:
c. Use suitable puller to remove oil seal (61) from 1. Individual Bearing Rollers. Remove 15 bearing
input bearing retainer (60). rollers (66A) and spacer 167).
d. Remove shim(s) (62) and bearing cup (63). 2. Roller Bearing Assembly. Remove bearing
assembly (66B).
h. Remove thrust bearing (68) and thrust race (69)
from end of output shaft (101).
3-14. REMOVAL OF T5 WC OUTPUT SHAFT
GROUP. Remove output shaft group from transmis-
sion as follows (see figure 3-8):
a. Remove one snap ring (56) and 5th driven gear
(70).
b. Push output shaft group (120) rearward to force
bearing cup (71) out of transmission case (117).
Remove bearing cup.
c. Tilt front end of output shaft group (120) up and
remove through top of case.
Figure 3-7. T5 WC Input Shaft

Figure 3-8. Removal of T5 WC Output Shaft Group
3-15. DISASSEMBLY OF T5WC OUTPUT SHAFT d. At other end of output shaft group, use suitable
GROUP. After removal from transmission, disassem- puller behind 3rd speed gear (83) to start parts off out-
ble output shaft group as follows (see figure 3-9): put shaft assembly (91). Remove two blocking rings
a. Use suitable puller behind 1 st speed gear (73) to (77), 3rd-4th synchronizer assembly (78) 3rd speed
pull gear and bearing cone (72). gear (83), bearing (84) and spacer (85).
b. Remove 1st speed gear bearing as follows accord- e. Refer to paragraph 3-20 for disassembly of 3rd-
ing to type: 4th synchronizer assembly.
1. One Double-Row Bearing. Remove bearing f. Remove snap ring (86), thrust washer (87), 2nd
(75A). speed gear (88) bearing (89) and spacer (90).
2. Two Separate Bearings. Remove two bearings g. Refer to paragrapn 3-16 for disassembly of out-
(75B) and spacer (75C). put shaft assembly (91).
c. Remove sleeve (76).
75B
BLOCKING RING
3RD-4TH SYNCHRO-
NIZER ASSY
83 3RD SPEED GEAR
84 NEEDLE BEARING
72. BEARING CONE 85. SPACER
73. 1ST SPEED GEAR 86. SNAP RING
77 74. BEARING SLEEVE 87. THRUST WASHER
ASSY 88 2ND SPEED GEAR
75A. BEARING 89 BEARING
75B. BEARING 90 SPACER
75C. SPACER 91 OUTPUT SHAFT
76. SLEEVE ASSY
T5146
Figure 3-9. Disassembly of T5 WC Output Shaft Group
3-7
3-16. DISASSEMBLY OF T5 WC OUTPUT SHAFT 3-17. REMOVAL OF T5WC REVERSE FORK AND
ASSEMBLY (see figure 3-10): IDLER GEAR (see figure 3-11):
a. Remove retaining ring (92) and thrust washer a. Unhook and remove spring (102) and fork pin and
(93). roller assembly (103).
b. From each end of shaft and hub assembly (101), b. Bend down tabs on rear retainer (105) and remove
remove inner cone (94), outer cone race (95) and 1-2 bolts (104) and retainer. Remove shim(s) (106).
blocking ring (96). c. Drive out roll pin (107) holding reverse idler shaft
c. Mark reverse sliding gear (98) and hub on shaft (108) in transmission case (117).
and hub assembly (101) so that clutch teeth can be d. Push reverse idler shaft (108) out rear of trans-
assembled exactly as they were originally. mission case (117).
d. Unhook and remove springs (97). Slide reverse a Remove roll pin (107), reverse idler gear assem-
sliding gear (98) from hub on shaft and hub assembly bly (109) and o-ring (110) from transmission case (117).
(101), freeing inserts (99).
e. Remove pin (100).
f. Do not attempt to disassemble shaft and hub
assembly (101).
Figure 3-11. T5 WC Reverse Fork and Idler Gear
Figure 3-10. T5 WC Output Shaft Assembly
3
3-18. REMOVAL OF T5 WC COUNTERSHAFT 3-20. DISASSEMBLY OF T5 WC 3RD-4TH SYN-
GEAR (see figure 3-12): CHRONIZER ASSEMBLY. Mark synchronizer
a. Push countershaft gear (116) rearward to force sleeve (80) and hub (82) so that clutch teeth and faces
bearing cup (111) out of transmission case (117). can be assembled exactly as they were originally.
b. Tut front end of countershaft gear (116) up and Sleeve and hub are a matched set, selected at manufac-
remove from top of transmission case (117). ture. Disassemble as follows (see figure 3-14):
c Push bearing cup assembly (112) out of transmis- a. Unhook and remove springs (79).
sion case (117) and remove o-ring (113) from bearing b. Slide sleeve (80) from hub (82), freeing inserts
cup (114). (81).
d. Use suitable puller to remove bearing cones (115)
from countershaft gear (116) if necessary.
3-19. DISASSEMBLY OF T5 WC 5TH SYNCHRO-
NIZER ASSEMBLY. Mark synchronizer sleeve (47)
and hub (49) so that clutch teeth and faces can be
assembled exactly as they were originally. Sleeve and
hub are a matched set, selected at manufacture. Dis-
assemble as follows (see figure 3-13):
a. Unhook and remove springs (46).
b. Slide sleeve (47) from hub (49), freeing inserts
(48).
46. SYNCHRONIZER 48. INSERT

SPRING 49. SYNCHRONIZER
47. SYNCHRONIZER HUB
SLEEVE T5102
Figure 3-13. T5 WC 5th Synchronizer Assembly
111. BEARING CUP 79. SYNCHRONIZER 81. INSERT

112. BEARING CUP SPRING 82. SYNCHRONIZER
ASSY 80. SYNCHRONIZER HUB
113. O-RING SLEEVE T5100
114. BEARING CUP
115. BEARING CONE Figure 3-14. T5 WC 3rd-4th Synchronizer Assembly
116. COUNTERSHAFT
GEAR
117. CASE ASSY T5147
Figure 3-12. T5 WC Countershaft Gear
3-9
Section 4
T5 NWC Disassembly
4-1. GENERAL INFORMATION 4-6. T5 NWC TRANSMISSION

4-2. This section provides disassembly instructions DISASSEMBLY PROCEDURES
for the T5 NWC transmission. The transmission class 4-7. REMOVAL OF T5 NWC CONTROL LEVER
can be identified by the last three digits of the trans- AND HOUSING ASSEMBLY AND EXTERNAL
mission part number. NWC units are listed in Table COMPONENTS. Clean transmission exterior, sup-
4-1. If the number for the transmission to be disassem- port on suitable holding fixture and proceed as follows
bled is not listed in Table 4-1, refer to Section 3, T5 WC (see figure 4-1):
Disassembly. a. Remove fill and drain plugs (1) and drain all fluid
4-3. During disassembly, refer to the illustrations from transmission.
provided with the text. In addition, an exploded view b. Shift transmission into neutral at 3-4 position.
of the complete assembly can be seen on figure 5-2 CAUTION
in Section 5, Cleaning, Inspection, Repair or Failure to shift transmission into neutral at 3-4
Replacement. position before removing control lever and hous-
4-4. This section provides instructions for complete ing assembly may result in driving roll pin (9,
disassembly of the T5 NWC transmission as would be figure 4-2) into detent guide plate (18) when pin
the case for overhaul. If the transmission is not due is removed (paragraph 4-8).
for overhaul, and repair affecting specific parts is c. Remove screws (2).
required, disassemble only to the extent necessary to d. If necessary, use suitable knife to break sealant
gam access to these parts. Parts removed from the bond between control lever and housing assembly (3A
transmission as subassemblies or groups need not be or 3B) and extension (11 A) or adapter (11B). Remove
disassembled for repair unless they contain the control lever and housing assembly. Remove boot (4)
affected parts. Total disassembly is recommended to only if replacement is required.
ensure that all parts are absolutely clean. e. Remove vent and o-ring assembly (5A) or
4-5. REMOVAL AND INSTALLATION OF breather (5B).
TRANSMISSION. Refer to paragraphs 2-10 and 2-21. g. If used, remove neutral switch (6), pin (7) and wire
retainer (8).
Table 4-1. T5 NWC Transmissions

(Last Three Digits of Part Number. 1352-000-XXX)
001 047 thru 049 080 156
002 051 081 157
004 thru 008 052 083 thru 086 164
010 054 thru 056 102 166
012 058 107 170
013 059 108 181 thru 183
015 thru 018 061 110 185
026 thru 028 062 136 187
032 thru 035 065 thru 068 145 189 thru 193
042 070 thru 072 146 201
043 074 thru 078 151 206
211
4-1
1.PLUG
2. SCREW
3A. CONTROL LEVER &
HOUSING ASSY
3B. CONTROL LEVER &
HOUSING ASSY
4. BOOT
5A. VENT & O-RING
ASSY
5B. BREATHER
6. SWITCH ASSY
7. PIN
8. WIRE RETAINER
11 A. EXTENSION ASSY
11B. ADAPTER ASSY
^ \
T5145
Figure 4-1. T5 NWC Control Lever Housing & External Components
4-2
4-8. REMOVAL OF T5 NWC EXTENSION OR straight out from transmission casa Offset lever (14)
ADAPTER. With offset lever accessible and in neu- will slide off shifter shaft (23) with extension or
tral at 3-4 position (paragraph 4-7, step b), proceed as adapter.
follows (see figure 4-2): d. Remove offset lever (14), damper sleeve (15),
a. Using suitable drift, drive roll pin (9) into offset spring (17), ball (16) and oil seal (18) from extension
lever (14) and out of engagement with shifter shaft (11 A) or adapter (11B). Remove roll pin (9) if loose or
(23). Tap drift with hammer just until offset lever feels drive out of offset lever (14) if still partially installed.
free on shaft. Do not remove detent guide plate (12) or plug (13).
b. Remove bolts (10). a. Remove oiling funnel (19).
c If necessary, use suitable knife to break sealant
bond between extension or adapter (11A or 11B) and
transmission case (106). Pull extension or adapter
9. ROLL PIN
10. BOLT
11B. ADAPTER ASSY
, DETENT GUIDE
PLATE
13 PLUG
14 , OFFSET LEVER
15 . DAMPER SLEEVE
16 BALL
17 SPRING
18 OIL SEAL
19. OILING FUNNEL
23. SHIFTER SHAFT
106. CASE ASSY
T5141
Figure 4-2. T5 NWC Extension or Adapter
4-3
4-9. REMOVAL OF T5 NWC CASE COVER AND b. If necessary, use suitable knife to break sealant
DISASSEMBLY OF SHIFT FORKS. With transmis- bond between case cover (32) and transmission case
sion assembly upright, proceed as follows (see figure (106). Move case cover and attached parts toward
4-3): drain plug side of transmission approximately one
a. Remove bolts (20 and 21). inch, then lift straight up.
c. Drive out pin (22).
d. Slide out shifter shaft (23), freeing shift forks (24
and 25), selector arm assembly (27), interlock plate (28)
and selector plates (29) from case cover (32).
e. Remove inserts (26) from shift forks (24 and 25).
f. Remove o-ring (30) from case cover (32) but not
plug (31).
4-10. REMOVAL OF T5 NWC 5-R SHIFT LEVER
(see figure 4-4):
a. From inside transmission assembly, remove
retaining ring (33).
b. From outside transmission, remove pivot pin (34)
and back-up switch (35).
On some units, 5-R shift lever is permanently

attached to reverse fork, pin and roller assem-
bly (94B, figure 4-11). Removal of 5-R shift lever
as described in the following step must be
deferred until reverse fork, pin and roller assem-
bly is removed.
Figure 4-3. T5 NWC Case Cover Figure 4-4. T5 NWC 5-R Shift Lever
4-4
c. Work 5-R shift lever (36) out of engagement and c. To separate 5th shift fork (48) and shift rail
lift out top of transmission case (106). assembly (50), drive out roll pin (47). Remove inserts
(49) from fork.
4-11. REMOVAL OF T5 NWC 5TH SYNCHRO- d. Refer to paragraph 4-19 for disassembly of 5th
NIZER, SHIFT FORK AND GEAR. At rear of trans- synchronizer assembly.
mission case (106), remove parts as follows (see figure e. Remove blocking ring (51) and 5th speed drive
4-5): gear (52) from transmission.
a. Remove snap ring (37), thrust race (38), bearing
(39) and thrust race (40). 4-12. REMOVAL OF T5 NWC SPEEDOMETER
b. Simultaneously pull 5th synchronizer assembly GEAR. On models so equipped, remove speedometer
(41) and 5th shift fork (48) with attached shift rail gear as follows: (see figure 4-6):
assembly (50). a. Remove one snap ring (53).
b. Remove speedometer gear (54) from output shaft
(91) by one of the following methods, depending on
attachment method:
1. Disengage clip (55A) and remove speedometer
gear (54) and clip.
2. Slide speedometer gear (54) outward and
remove ball (55B).
Figure 4-6. T5 NWC Speedometer Gear

37. SNAP RING 48. 5TH SHIFT FORK
38. THRUST RACE 49. INSERT
39. BEARING 50. SHIFT RAIL ASSY
40. THRUST RACE 51. BLOCKING RING
41. 5TH SYNCHRO- 52. 5TH SPEED DRIVE
NIZER ASSY GEAR
47. ROLL PIN 106. CASE ASSY T513S
Figure 4-5. T5 NWC 5th Synchronizer,

Shift Fork and Gear
4-13. REMOVAL OF T5NWC INPUT SHAFT. Make e. Rotate input shaft (62) to align flat on its clutch
alignment mark on input bearing retainer (57) and tooth ring with countershaft (105) and remove from
transmission case (106) and proceed as follows (see transmission.
figure 4-7): f. If necessary, remove bearing cone (61) from input
a. Remove bolts (56). shaft (62) using suitable puller.
b. If necessary, use suitable knife to break sealant g. Remove 15 bearing rollers (63) installed between
bond between input bearing retainer (57) and trans- input shaft (62) and output shaft (91).
mission case (106). Pull bearing retainer straight out. h. Remove thrust bearing (64) and thrust race (65)
c. Use suitable puller to remove oil seal (58) from from end of output shaft (91).
input bearing retainer (57). 4-14. REMOVAL OF T5 NWC OUTPUT SHAFT
d. Remove shim(s) (59) and bearing cup (60). GROUP. Remove output shaft group from transmis-
sion as follows (see figure 4-8):
a. Remove one snap ring (53) and 5th driven gear
(66).
b. Push output shaft group (120) rearward to force
bearing cup (67) out of transmission case (106).
Remove bearing cup.
a Tilt front end of output shaft group (120) up and
remove through top of case.
67 BEARING CUP
106 CASE ASSY
53. SNAP RING 120 OUTPUT SHAFT
66. 5TH DRIVEN GEAR GROUP
56. BOLT 63. BEARING ROLLER
57. INPUT BEARING 64. THRUST BEARING
RETAINER 65. THRUST RACE
Figure 4-8. Removal of T5 NWC
58. OIL SEAL 91.
Output Shaft Group
OUTPUT SHAFT
59. SHIM 105. COUNTERSHAFT
60. BEARING CUP GEAR
61. BEARING CONE 106. CASE ASSY
62. INPUT SHAFT T5133
Figure 4-7. T5 NWC Input Shaft
4-6
4-15. DISASSEMBLY OF T5 NWC OUTPUT d. Refer to paragraph 4-20 for disassembly of 3rd-
SHAFT GROUP. After removal from transmission, 4th synchronizer assembly.
disassemble output shaft group as follows (see figure a Remove snap ring (80), thrust washer (81) and
4-9): 2nd speed gear (82).
a. Use suitable puller behind 1st speed gear (70) to f. Refer to paragraph 4-16 for disassembly of out-
pull gear, thrust washer (69) and bearing cone (68). put shaft assembly (83).
b. Remove needle bearing (71) and thrust race (72).
c. At other end of output shaft group, use suitable
puller behind 3rd speed gear (79) to start parts off out-
put shaft assembly (83). Remove two blocking rings
(73), 3rd-4th synchronizer assembly (74) and 3rd speed
gear (79).
BEARING C O N E
THRUST WASHER
1ST SPEED GEAR
NEEDLE BEARING
THRUST RACE
73. BLOCKING RING
74. 3RD-4TH SYNCHRO-
NIZER ASSY
79. 3RD SPEED GEAR
80. SNAP RING
81. THRUST W A S H E R
82. 2ND SPEED GEAR
83. OUTPUT SHAFT
ASSY
T5131
Figure 4-9. Disassembly of T5 NWC Output Shaft Group
4-7
416. DISASSEMBLY OF T5 NWC OUTPUT 4-17. REMOVAL OF T5 NWC REVERSE FORK
SHAFT ASSEMBLY (see figure 4- 10): AND IDLER GEAR (see figure 4-11):
a. From each end of shaft and hub assembly (91), a. Depending on construction used, remove parts
remove 1-2 blocking ring (84). by one of the two following methods:
b. Mark reverse sliding gear (86) and hub on shaft 1. Unhook and remove spring (92A) and fork, pin
and hub assembly (91) so that clutch teeth can be and roller assembly (94A).
assembled exactly as they were originally. 2. Unhook and remove spring (92B), hook (93)
c. Unhook and remove springs (85). Slide reverse and fork, pin and roller assembly (94B) (with attached
sliding gear (86) from hub on shaft and hub assembly lever).
(91), freeing inserts (87). b. Remove snap ring (95) and thrust washer (96).
d. Depending on which is used, remove pin (88), or c. Drive out roll pin (97) holding reverse idler shaft
ball (89) and spring (90). (98) in transmission case (106).
e. Do not attempt to disassemble shaft and hub d. Push reverse idler shaft (98) out rear of transmis-
assembly (91). sion case (106).
e. Remove roll pin (97), reverse idler gear assembly
(99) and o-ring (100) from transmission case (106).
Figure 4-10. T5 NWC Output Shaft Assembly
Figure 4-11. T5 NWC Reverse Fork and Idler Gear
4-8
4-18. REMOVAL OF T5 NWC COUNTERSHAFT
GEAR (see figure 4-12):
a. Push countershaft gear (105) rearward to force
bearing (101) and spacer (102) out of transmission case
(106).
b. Tilt front end of countershaft gear (105) up and
remove from top of transmission case (106).
c. Press bearing (103) from transmission case (106).
Remove thrust washer (104).
4-19. DISASSEMBLY OF T5 NWC 5TH SYN-
CHRONIZER ASSEMBLY. Mark synchronizer
sleeve (44) and hub (46) so that clutch teeth and faces
can be assembled exactly as they were originally.
Sleeve and hub are a matched set, selected at manufac- 42. RETAINER
ture. Disassemble as follows (see figure 4-13): 43. SYNCHRONIZER
a. Remove retainer (42). SPRING
b. Unhook and remove springs (43). 44. SYNCHRONIZER
c. Slide sleeve (44) from hub (46), freeing inserts (45). SLEEVE
4-20. DISASSEMBLY OF T5 NWC 3RD-4TH SYN- 45. INSERT
CHRONIZER ASSEMBLY Mark synchronizer sleeve 46. SYNCHRONIZER
(76) and hub (78) so that clutch teeth and faces can be HUB
assembled exactly as they were originally. Sleeve and T5125
hub are a matched set, selected at manufacture. Dis-
assemble as follows (see figure 4-14): Figure 4-13. T5 NWC 5th Synchronizer Assembly
a. Unhook and remove springs (75).
b. Slide sleeve (76) from hub (78), freeing inserts
(77).
75. SYNCHRONIZER
SPRING
76. SYNCHRONIZER
SLEEVE
77. INSERT
78. SYNCHRONIZER
HUB
Figure 4-14. T5 NWC 3rd-4th Synchronizer Assembly
101. BEARING 105. COUNTERSHAFT

102. SPACER GEAR
103. BEARING 106. CASE ASSY
104. THRUST WASHER T51Z7
Figure 4-12. T5 NWC Countershaft Gear
4-9
Section 5
T5 WC & NWC Cleaning, Inspection, Repair or
Replacement
5-1. CLEANING 5-4. LUBRICATING BEARINGS. Immediately

NOTE after cleaning, lubricate anti-friction bearings listed
below with transmission lubricant (refer to paragraph
Prior to cleaning transmission case, check mag- 2-4). Rotating or spinning dry, unlubricated bearings
net cemented in case bottom for presence of could result m damage. Cover lubricated bearings to
metal particles. Larger, granular or irregular protect from dust.
shaped particles indicate chipping or similar a. T5 WC Anti-Friction Bearings (see figure 5-1):
damage. Smaller, powder-like particles indicate Bearing cone (64)
uneven or excessive wear. If metal particles are Bearing rollers (66A) or bearing assy (66B)
detected, be on the lookout for damage or wear Thrust bearing (68)
when inspecting rotating parts and those with Bearing cone (72)
which they mate. Bearing (75A) or bearing (75B)
5-2. GENERAL CLEANING PROCEDURE. Care- Needle Dearing (84)
fully scrape parts to remove old sealant using care not 2nd speed bearing (89)
to damage metal surfaces. Wash parts in cleaning sol- Bearing cones (115)
vent to remove old lubricant and dirt deposits. Use a b. T5 NWC Anti-Friction Bearings (see figure 5-2):
bristle brush to remove caked-on deposits. Parts that Bearing (39)
cannot be cleaned by brushing may be scraped but use Bearing cone (61)
care not to damage metal surfaces. Bearing rollers (63)
Thrust bearing (64)
5-3. DRYING CLEANED PARTS. Dry parts with Bearing cone (68)
low pressure (20 psi max) compressed air. Wiping parts Needle Dearing (71)
dry could leave lint deposits. Hold bearings to prevent Bearing (101)
them from spinning when drying. Bearing (103)
5-1
Figure 5-1. T5 WC Manual Transmission
5-2
LEGEND FOR T5 WC, FIGURE 5-1
• Used on specific models

NP = Not Procurable
5-3
LEGEND FOR T5 WC, FIGURE 5-1 (CONT)
•Used on specific models

NP = Not Procurable
AR = As Required
5-4
Figure 5-2. T5 NWC Manual Transmission
5-5
LEGEND FOR T5 NWC, FIGURE 5-2
INDEX
NO. DESCRIPTION QTY
1 Plug, Fill/Drain 2
2 Screw 4
3A •Control Lever & Housing Assy
3B •Control Lever & Housing Assy
4 ••Boot
5A •Vent & O-Ring Assy
5B •Breather
6 •Switch Assy, Neutral
7 •Pin
8 •Retainer, Wire
9 Pin, Roll
10 Bolt
11A •Extension, Bushing & Plate Assy
11B •Adapter & Plate Assy
12 •Plate, Detent Guide
13 •Plug
14 Lever, Offset
15 Sleeve, Damper
16 Ball
17 Spring
18 Seal, Oil
19 Funnel, Oiling
20 Bolt
21 Bolt, Alignment
22 Pin, Selector Arm
23 Shaft, Shifter
24 Fork, Shift, 3-4
25 Fork, Shift, 1-2
26 Insert
27 Arm Assy, Selector
28 Plate, Interlock
29 Plate, Selector
30 O-Ring
31 Plug
32 Cover, Case
33 Ring, Retaining
34 Pin, Pivot
35 Switch, Back-Up
36 •Lever, Shift, 5-R
37 Ring, Snap
38 Race, Thrust
39 Bearing
40 Race, Thrust
41 Synchronizer Assy, 5th
42 •Retainer, 5th Synchronizer
43 •Spring, Synchronizer 2
44 •Sleeve, Synchronizer NP
45 •Insert 3
46 •Hub, Synchronizer NP
47 Pin, Roll
48 Fork, Shift, 5th
49 Insert
50 Rail Assy, Shift 1
51 Ring, Blocking
52 Gear, 5th Speed Drive
53 Ring, Snap
54 •Gear, Speedo
55A •Clip, Speedo Gear
55B •Ball
56 Bolt
57 Retainer, Input Bearing
58 Seal, Oil
59 Shim AR
60 Cup, Bearing 1
NP = Not Procurable
AR = As Required 5-6
LEGEND FOR T5 NWC, FIGURE 5-2 (CONT)
INDEX
NO. DESCRIPTION QTY
61 Cone, Bearing
62 Shaft, Input
63 Roller, Bearing 15
64 Bearing, Thrust, Needle
65 Race, Thrust
66 Gear, 5th Driven
67 Cup, Bearing
68 Cone, Bearing
69 Washer, Thrust
70 Gear, 1st Speed
71 Bearing, Needle
72 Race, Thrust
73 Ring, Blocking 2
74 Synchronizer Assy, 3rd-4th 1
75 •Spring, Synchronizer 2
76 •Sleeve, Synchronizer NP
77 •Insert 3
78 •Hub, Synchronizer NP
79 Gear, 3rd Speed
80 Ring, Snap
81 Washer, Thrust
82 Gear, 2nd Speed
83 Shaft Assy, Output
84 •Ring, 1-2 Blocking
85 •Spring
86 •Gear, Reverse Sliding
87 •Insert
88 ••Pin
89 ••Ball
90 ••Spring
91 •Shaft and Hub Assy
92A •Spring
92B •Spring
93 •Hook
94A •Fork, Pin & Roller Assy, Reverse
94B •Fork, Pin & Roller Assy, Reverse
95 Ring, Snap
96 Washer, Thrust
97 Pin, Roll
98 Shaft, Reverse Idler
99 Gear Assy, Reverse Idler
100 O-Ring
101 Bearing
102 Spacer
103 Bearing
104 Washer, Thrust
105 Gear, Countershaft
106 Case Assy, Transmission
NP = Not Procurable
5-7
5-5. INSPECTION a. Check gear tooth contact patterns. Contact pat-
terns likely to be encountered are shown in figure 5-4.
5-6. GENERAL INSPECTION PROCEDURES. Parts with contact patterns shown in the ACCEPT
Visually inspect all parts except o-rings and oil seals, column are OK for further service provided they meet
which should be replaced with new parts, or parts in all other inspection requirements. Parts with contact
kit if service kit is used. Inspect for damage or exces- patterns shown in REJECT column are unacceptable
sive or uneven wear. Reject parts with damage or wear and must be rejected—no repairs are authorized.
that would affect serviceability of the part. Inspection b. Check gear teeth for chips. Compare tooth chips
terms used in this section are as follows: or nicks with those shown in figure 5-5. Parts with
Burr: Local rise of material forming protruding sharp small chips as shown in REPAIR column may be
edge blend-repaired (refer to paragraph 5-12) and reused.
Chips or broken teeth as shown in REJECT column
Chip: An area from which a small fragment has been are not repairable and the part must be rejected.
broken off or cut. c. Check clutch teeth. Inspect clutch teeth for
rounding as shown in figure 5-6. Face rounding will
Crack: Surface break of line nature indicating partial cause the clutch to jump out Reject such parts. Clutch
or complete separation of material teeth with rounding on the end are usable but will
cause hard shifting. In general, clutch teeth with chips
Excessive wear: Heavy or obvious wear beyond expec- may be blend-repaired in the same manner as gear
tations considering conditions of operation. teeth (figure 5-5) except as shown on figure 5-6.
Indentation: Displacement of material caused by

localized heavy contact.
Galling: Breakdown (or build-up) of metal surface due
to excessive friction between parts. Particles of the
softer material are torn loose and welded to the harder
material.
Nick: Local break or notch. Usually displacement of ACCEPT GEARS
material rather than loss. WITH NORMAL
NORMAL GEAR TOOL MARKS
Scoring: Tear or break in metal surface from contact SHAVE MARKS BUT REJECT IF
under pressure. May show discoloration from heat ROUGHNESS OR
produced by friction.
RIDGES ARE
Step wear: Heavy wear that produces a step that can PRESENT ON
be seen or felt between adjacent contact and non- TOOTH FACE
contact surfaces.
Uneven wear: Condition of localized, unevenly dis-
tributed wear. Includes hollows, shiny spots, uneven NORMAL GEAR
polish and other visual indications.
GRIND MARKS
5-7. SPECIFIC INSPECTION PROCEDURES.
Inspect parts in accordance with Table 5-1 (T5 WC) Figure 5-3. Normal Gear Tooth Tool Marks
or 5-2 (T5 NWC) and as specified in the following para-
graphs. Index numbers used in Table 5-1 and 5-2 are
those assigned to exploded view figures 5-1 (T5 WC)
and 5-2 (T5 NWC).
5-8. GEAR OR CLUTCH TEETH INSPECTION.
When specified in Table 5-1 or 5-2, inspect gear or
clutch teeth as follows:
NOTE
Do not confuse contact patterns with normal
tool marks that are a result of manufacture.
Typical tool marks are shown in figure 5-3.
5-9. SPLINE TEETH INSPECTION. Check for
broken or chipped spline teeth. Small chips may be
blend-repaired in same manner as gear teeth (see
figure 5-4 and refer to paragraph 5-12). If any spline
tooth is broken, the part must be rejected. Spline teeth
will not show contact patterns as gear teeth da
However, they may show evidence of step wear which
is cause for rejection.
DESCRIPTION ACCEPT REJECT
DESIRED CONTACT
PATTERN
END CONTACT
PATTERN
TRAVELING CONTACT
PATTERN
(MOVES FROM SIDE TO SIDE)
HIGH CONTACT
PATTERN
LOW CONTACT PATTERN
18461
Figure 54. Gear Tooth Contact Patterns
5-9
Table 5-1. T5 WC Parts Inspection
PART (FIG. 5-1
INDEX NO.) INSPECTION ACCEPT/REJECT
All parts (including Jll Check for cracks Replace parts with cracks
springs) Check for distortion Replace parts that are bent, dis-
torted or out of round
All threaded parts Check for stripped, crossed or other- Replace parts with threads that
wise damaged threads cannot be cleaned up using a suit-
able tap or die
Control lever and housing Check mating faces for burrs or Remove small burrs per paragraph
assy (3A, 3B or 3C), exten- other damage that would prevent 5-13. Otherwise replace damaged
sion (17A) or adapter (17B), proper seating of mating faces parts
case cover (38) and transmis-
sion case (117)
Control lever and housing Check for smooth operation without Replace assy if control lever binds
assy (3A, 3B or 3C) excessive end or side play or operates with excessive play in
housing
Control lever and housing Check mating operating surfaces for Replace parts/assemblies that are
assy (3A, 3B or 3C), damper scoring or excessive wear excessively worn or damaged
sleeve (21) and offset lever
(20)
Extension, bushing and plate Check bushing ID for scoring or Replace assy if bushing is damaged
assy (17A) other damage
Extension, bushing and plate Check detent guide plate (18) for Replace assy if detent guide plate
assy (17A) or adapter and scoring, excessively worn grooves or damaged or excessively worn
plate assy (17B) other damage
Ball (22) Check for grooves or flat spots Replace damaged ball
Shifter shaft (29) and shift Check for distortion Replace bent parts
rail assy (53) Check for grooves, burrs or other Remove small burrs per paragraph
damage 5-13. Otherwise replace damaged
parts
Check OD for wear Replace if step wear found
Shift forks (30 and 31) Check for scored or worn bore for Replace damaged forks
shaft
Chipped or broken tabs for inserts Replace damaged forks
Inserts (32 and 52) Check for wear Replace if step wear or grooves
found
Selector arm assy (33), inter- Check for wear or scoring Replace if scoring, worn edges or
lock plate (34) and selector step wear found
plates (35)
Pivot pin (40) Check for scoring or wear on bearing Replace if scoring or step wear
surface found
5-R shift lever (42) Check pin bore and cam groove for Replace if scoring or step wear
scoring or wear found
Synchronizer sleeves (47 and Engage sleeve with mating hub, Replace complete synchronizer
80) and hubs (49 and 82) aligning index marks. Check that assembly if there is binding or rota-
parts slide freely but without rotational play
tional play
Clutch teeth per paragraph 5-8 Paragraph 5-8
5-10
Table 5-1. T5 WC Parts Inspection (Cont)
PART (FIG. 5-1
Synchronizer sleeves (47 and Check fork grooves for wear or Replace complete synchronizer
80) damage assembly if step wear or scoring
found
Synchronizer hubs (49 and Check splines per paragraph 5-9) Paragraph 5-9
82)
Check insert grooves for burrs, step Remove small burrs per paragraph
wear or damage 5-13. Replace complete syn-
chronizer assembly if step wear or
damage found
Inserts (48 and 80) Check for burrs, grooves or step Remove small burrs per paragraph
wear 5-13. Replace inserts if grooves or
step wear found
Shift fork (51) Check for damage to pin hole that Replace damaged fork
would prevent fork from being held
securely on shifter shaft
Chipped or broken tabs for inserts Replace damaged fork
Shift rail assembly (53) Check that cam roller turns freely. Replace shift rail if roller binds or
Check for scoring or step wear on is worn or damaged
roller
Blocking rings (54, 77 and 96) Check clutch teeth per paragraph 5-8 Paragraph 5-8
Check index slots for wear or Replace if index slots show step
damage wear or damage
Blocking rings (54, 77 and Check friction surfaces for excessive Replace worn or damaged parts
96) and cones (95 and 96) wear, scoring or other damage
Gears (55, 57, 65, 70, 73, 83, Check gear teeth per paragraph 5-8 Paragraph 5-8
88, 98, 109 and 116)
Gears (55, 65, 73, 83, 88 and Check clutch teeth per paragraph 5-8 Paragraph 5-8
98)
Gears (55, 73, 83, 88 and Check bearing bores Replace if scored or excessively
109) worn
Input bearing retainer (60) Check bearing bore Replace if scored or excessively
worn
Bearing cups (63, 71, 111 Check cups, rollers and races for Replace damaged bearing cups or
and 112) and cones (64, 72 chipping, galling scoring or other cones
and 115) damage
Make sure bearing cone is lubri- Replace bearing cones with loose or
cated. Slowly rotate rollers, feeling damaged rollers
for binding, roughness or flat spots.
Rollers must rotate smoothly
without side or end play
Shafts (65, 101 and 108) Check for distortion Replace shafts that are bent or out
of round
Check bearing journals Replace if scored or damaged
5-11
Table 5-1. T5 WC Parts Inspection (Cont)
PART (FIG. 5-1
Shafts (65) and 101) Check splines per paragraph 5-9) Paragraph 5-9
Needle bearings and rollers Check rollers and races for chipping, Replace damaged bearings and
(66A, 66B, 68, 75A, 75B, 84, galling, scoring or other damage rollers
and 89)
Bearing thrust races, Check for scoring or excessive wear Replace parts that show step wear,
washers, spacers, and sleeves are scored or otherwise damaged
(69, 75C, 76, 85, 87, 90 and
93)
5th drive gear (70) Check splines per paragraph 5-9 Paragraph 5-9
Reverse sliding gear (98) and Check fork grooves for wear or Replace gear if step wear or scoring
reverse idler gear (109) damage found
Hub on shaft and hub assy Engage gear with hub, aligning Replace parts if there is binding or
(101) and reverse sliding gear index marks. Check that parts slide rotational play
(98) freely without rotational play
Check clutch teeth per paragraph 5-8 paragraph 5-8
Fork, pin and roller assy Check for worn bore for shaft Replace worn or damaged assembly
(103)
Check that cam roller turns freely. Replace worn or damaged assembly
Check for scoring or step wear on
roller
Check shift tabs for wear or damage Replace if step wear, grooves or
chipped or broken shift tabs found
Countershaft gear (116) Check for distortion Replace if bent our out of round
Check splines per paragraph 5-9 Paragraph 5-9
Transmission case (117) Check bearing bores Replace case if bearing bores
scored or damaged
5-12
Table 5-2. T5 NWC Parts Inspection
PART (FIG. 5-2
All parts (including all » Check for cracks Replace parts with cracks
springs)
Check for distortion Replace parts that are bent, dis-
torted or out of round
All threaded parts Check for stripped, crossed or other- Replace parts with threads that
wise damaged threads cannot be cleaned up using a suit-
able tap or die
Control lever and housing Check mating faces for burrs or Remove small burrs per paragraph
assy (3A or 3B) extension other damage that would prevent 5-13. Otherwise replace damaged
(11A) or adapter (11B), case proper seating of mating faces parts
cover (32) and transmission
case(106)
Control lever and housing Check for smooth operation without Replace assy if control lever binds
assy (3A or 3B) excessive end or side play or operates with excessive play in
housing
Control lever and housing Check mating operating surfaces for Replace parts/assemblies that are
assy (3A or 3B), damper scoring or excessive wear excessively worn or damaged
sleeve (15) and offset lever (14)
Extension, bushing and plate Check bushing ID for scoring or Replace assy if bushing is damaged
assy (11 A) other damage
Extension, bushing and plate Check detent guide plate (12) for Replace assy if detent guide plate
assy (11 A) or adapter and scoring, excessively worn grooves or damaged or excessively worn
plate assy (11B) other damage
Ball (16 and 89) Check for grooves or flat spots Replace damaged ball
Shifter shaft (23) and shift Check for distortion Replace bent parts
rail assy (50)
Check for grooves, burrs or other Remove small burrs per paragraph
damage 5-13. Otherwise replace damaged
parts
Check OD for wear Replace if step wear found
Shift forks (24 and 25) Check for scored or worn bore for Replace damaged forks
shaft
Chipped or broken tabs for inserts Replace damaged forks
Inserts (26 and 49) Check for wear Replace if step wear or grooves
found
Selector arm assy (27), inter- Check for wear or scoring Replace if scoring, worn edges or
lock plate (28) and selector step wear found
plates (29)
Pivot pin (34) Check for scoring or wear on bearing Replace if scoring or step wear
surface found
5-R shift lever (36) or fork, Check pin bore and cam groove for Replace if scoring or step wear
pin and roller assy (94B) scoring or wear found
5-13
Table 5-2. T5 NWC Parts Inspection (Cont)
PART (FIG. 5-2
Synchronizer sleeves (44 and Engage sleeve with mating hub, Replace complete synchronizer
76) and hubs (46 and 78) aligning index marks. Check that assembly if there is binding or rota-
parts slide freely but without rotational play
tional play
Clutch teeth per paragraph 5-8 Paragraph 5-8
Synchronizer sleeves (44 and Check fork grooves for wear or Replace complete synchronizer
76) damage assembly if step wear or scoring
found
Synchronizer hubs (46 and 78) Check splines per paragraph 5-9 Paragraph 5-9
Check insert grooves for burrs, step Remove small burrs per paragraph
wear or damage 5-13. Replace complete syn-
chronizer assembly if step wear or
damage found
Inserts (45, 77 and 87) Check for burrs, grooves or step wear Remove small burrs per paragraph
5-13. Replace inserts if grooves or
step wear found
Shift fork (48) Check for damage to pin hole that Replace damaged fork
would prevent fork from being held
securely on shifter shaft
Chipped or broken tabs for inserts Replace damaged fork

Shift rail assembly (50) Check that cam roller turns freely. Replace shift rail if roller binds or
Check for scoring or step wear on is worn or damaged
roller
Blocking rings (51, 73 and 84) Check clutch teeth per paragraph 5-8 Paragraph 5-8
Check index slots for wear or damage Replace if index slots show step
wear or damage
Check friction surfaces for excessive Replace worn or damaged parts

wear, scoring or other damage
Gears (52, 54, 62, 66, 70, 79, Check gear teeth per paragraph 5-8 Paragraph 5-8
82, 86, 99 and 105)
Gears (52, 62, 70, 79, 82 and Check clutch teeth per paragraph 5-8 Paragraph 5-8
86)
Gears (52, 70, 79, 82 and 99) Check bearing bores Replace if scored or excessively worn
Input bearing retainer (57) Check bearing bore Replace if scored or excessively worn
Bearing cups (60 and 67), Check cups, races and rollers or balls Replace damaged bearing cups or
cones (61 and 68) and for chipping, galling scoring or other cones, or ball bearings
bearings (101 and 103) damage
Make sure bearing cone or bearing is Replace bearing cones or bearings

lubricated. Slowly rotate rollers or with loose or damaged rollers or
ball bearings, feeling for binding, races
roughness or flat spots. Rollers or
balls must rotate smoothly without
side or end play
5-14
liable 5-2. T5 NWC Parts Inspection (Cont)
PART (FIG. 5-2
Shafts (62, 91 and 98) Check for distortion Replace shafts that are bent or out
of round

Shafts (62) and 91) Check splines per paragraph 5-9) Paragraph 5-9
Needle bearings and rollers Check rollers and races for chipping, Replace damaged bearings and
(39, 63, 64 and 71) galling, scoring or other damage rollers
Bearing thrust races, Check for scoring or excessive wear Replace parts that show step wear,
washers, spacers, and sleeves are scored or otherwise damaged
(38, 40, 65, 72, 81, 96, 102
and 104)
5th driven gear (66) Check splines per paragraph 5-9 Paragraph 5-9
Reverse sliding gear (86) and Check fork grooves for wear or Replace gear if step wear or scoring
reverse idler gear (99) damage found
Hub on shaft and hub assy Engage gear with hub, aligning Replace parts if there is binding or
(91) and reverse sliding gear index marks. Check that parts slide rotational play
(86) freely without rotational play
Check clutch teeth per paragraph 5-8 paragraph 5-8
Fork, pin and roller assy Check for worn bore for shaft Replace worn or damaged assembly
(94A or 94B)
Check that cam roller turns freely. Replace worn or damaged assembly
Check for scoring or step wear on
roller
Check shift tabs for wear or damage Replace if step wear, grooves or
chipped or broken shift tabs found
Countershaft gear (105) Check for distortion Replace if bent our out of round
Check splines per paragraph 5-9 Paragraph 5-9

Transmission case (106) Check bearing bores Replace case if bearing bores
scored or damaged
5-15
5-10. REPAIR OR REPLACEMENT 5-14. PARTS REPLACEMENT. Replace rejected
parts that are not repairable If there is any doubt
5-11. Parts which are rejected at inspection shall be about the serviceability of a part, replace it.
replaced unless repair procedures specified in the fol-
lowing paragraphs, or other obvious minor repair, will 5-15. SERVICE KIT. A service kit, containing bear-
restore the part to complete serviceability. ings, snap rings, oil seals and other small parts that
normally require replacement, may be available Refer
5-12. GEAR AND CLUTCH TOOTH REPAIR. to the Borg-Warner T5 Transmission Parts Catalog for
Repair shall be limited to blend-repair of chips within availability and part number.
the limits shown in figure 5-5 and 5-6.
a. Blend-repair chips using a suitable hand-held, 5-16. SYNCHRONIZER ASSEMBLIES. The follow-
high speed grinding tool ing parts are matched sets, selected at manufacture
b. Blend chip into surrounding base metal, but do If either part of the matched set must be replaced,
not remove any more metal than necessary. replace the complete synchronizer assembly:
c. Blend all sharp edges into smooth contour. Sharp a. T5 WC Synchronizer Assemblies:
edges may chip again or develop cracks. 5th synchronizer assembly (45, figure 5-1)
3rd-4th synchronizer assembly (78, figure 5-1)
5-13. REMOVING SMALL BURRS. Use a suitable b. T5 NWC Synchronizer Assemblies:
abrasive stone to remove burrs. Be careful to remove 5th synchronizer assembly (41, figure 5-2)
only raised material, not base metaL 3rd-4th synchronizer assembly (74, figure 5-2)
REPAIR REJECT
CORNER CHIP WITHIN

CHIP AT CONTACT
DRIVE FACE PATTERN
O.D. EDGE
CHIP AT CHIP
DRIVE FACE. COMPLETELY
MAY EXTEND THROUGH TOOTH
SLIGHTLY INTO (CONSIDERED TO
CONTACT BE BROKEN)
PATTERN
CORNER
CHIP AT
COAST FACE
SIDE EDGE
CHIP AT
DRIVE FACE
1847
Figure 5-5. Gear Tooth Chips
5-16
Figure 5-6. Clutch Tooth Inspection
5-17
Section 6
T5 WC Assembly
6-1. GENERAL INFORMATION NOTE

6-2. During assembly, refer to the illustrations speci- If synchronizer assembly is replaced, do not
fied in the text. In addition, an exploded view of the separate parts. Skip this paragraph and install
complete assembly can be seen on figure 5-1 in Sec- assembly as received.
tion 5, Cleaning, Inspection, Repair or Replacement.
Note the following during assembly:
a. When a torque value is specified, use a torque
wrench to tighten the threaded part. Torque values are
specified in the text and also in Table 6-1 at the end
of this section.
b. Coat small parts with petrolatum to help hold
them in place during assembly.
6-3. LUBRICATION DURING ASSEMBLY. Lubri-
cate all internal parts, not coated with petrolatum,
with approved transmission lubricant (refer to para-
graph 2-4) just prior to assembly. This will ease assem-
bly and provide initial lubrication.
a. O-rings and shaft seal lips may be damaged dur-
ing assembly if not lubricated.
b. Make sure all bearings (refer to paragraph 6-5)
are thoroughly lubricated before assembly. Running
bearings dry, even for a brief period, will cause
damage.
c. Before assembly, immerse T5 WC blocking ring
assemblies (77, figure 5-1) and outer cone races (95) in
approved transmission lubricant for at least one
minute to thoroughly soak lining material. Soaked Figure 6-1. T5 WC 3rd-4th Synchronizer Assembly
parts must be installed in transmission within 48
hours.
6-4. T5 WC TRANSMISSION ASSEMBLY a. Start sleeve (80) onto hub (82) to a position that
PROCEDURES will just permit installation of inserts (81). Install
inserts (81) then engage clutch teeth fully.
6-5. T5 WC BEARING LUBRICATION. Before b. Hook one end of one spring (79) under one of the
assembly, make sure that each of the following anti- inserts (81) and wrap around inside, under all three
friction "bearings is thoroughly lubricated (refer to inserts. Hook other end of spring under insert (see
paragraph 6-3 and see figure 5-1): figure 6-2).
Bearing cone (64) c Invert assembly. Hook remaining spring (79)
Bearing rollers (66A) or bearing assy (66B) under opposite end and side of same insert (81) where
Thrust bearing (68) step b was started but wrap around inside in opposite
Bearing cone (72) direction from step b, under all three plates. Hook
Bearing (75A) or bearing (75B) other end of spring under insert (81) (see figure 6-2).
Needle bearing (84) d. Position sleeve (80) and inserts (81) so that all
2nd speed bearing (89) inserts snap into neutral position.
Bearing cones (115) a Set 3rd-4th synchronizer aside for later installa-
6-6. ASSEMBLY OF T5WC3RD-4TH SYNCHRO- tion in transmission.
NIZER ASSEMBLY (see figure 6-1). Be sure to assem-
ble sleeve (80) and hub (82) aligning marks made at
disassembly (see figure 6-2) so that clutch teeth and
part faces are assembled exactly as they were origi-
nally. Assemble as follows:
CAUTION
Failure to assemble synchronizer sleeve and hub
as they were originally could result in unsatis-
factory performance.
6-1
6-7. ASSEMBLY OF T5 WC 5TH SYNCHRO-
disassembly (see figure 6-4) so that clutch teeth and
part faces are assembled exactly as they were origi-
nally. Assemble as follows:
CAUTION
NOTE
If synchronizer assembly is replaced, do not
separate parts. Skip this paragraph and install
assembly as received.
a. Start sleeve (47) onto hub (49) to a position that
will just permit installation of inserts (48). Install
b. Hook one end of one spring (46) under one of the
inserts (48) and wrap around inside, under all three Figure 6-4. T5 WC 5th Synchronizer Assembled
inserts. Hook other end of spring under insert (see
figure 6-4).
c. Invert assembly. Hook remaining spring (46)
under opposite end and side of same insert (48) where
step b was started but wrap around inside in opposite
direction from step b, under all three plates. Hook
other end of spring under insert (48) (see figure 6-4).
d. Position sleeve (47) and inserts (48) so that all
inserts snap into neutral position.
e. Set 5th synchronizer aside for later installation
in transmission.
Figure 6-3. T5 WC 5th Synchronizer Assembly
Figure 6-2. T5 WC 3rd-4th Synchronizer

Assembled
6-2
6-8. ASSEMBLY AND INSTALLATION OF T5WC 6-9. INSTALLATION OF T5WC REVERSE FORK
COUNTERSHAFT GEAR (see figure 6-5): AND IDLER GEAR. With assembly completed as
a If replaced, press bearing cones (115) on counter- described through paragraph 6-8, proceed as follows
shaft gear (116) using suitable tubular drift that con- (see figure 6-6):
tacts only bearing cone inner raca Press on bearing a. Start reverse idler shaft (108) in through rear
cones to bottom out on shaft shoulders. opening in transmission case (117) with pin hole in
b. Install o-ring (113) in groove in OD of bearing cup shaft pointing up toward top case opening.
(114) and press cup into transmission case until cup b. Position o-ring (110) and reverse idler gear assem-
flange seats against inside face of casa bly (109) in transmission case (117) and continue to
c Install countershaft gear (116), with bearing push reverse idler shaft into casa through gear, o-ring
cones (115) through top opening of transmission case and boss inside casa
(117), rear end first. Extend rear end of countershaft c. Install roll pin (107). Using suitable drift, tap pin
gear through rear case opening enough to seat front into reverse idler shaft (108) until pin is centrally
end bearing cone in bearing cup (114). located in shaft.
d. Temporarily install bearing cup (111) and attach d. Install bearing cup (111) with shim(s) (106)
rear retainer (105) with bolts (104). selected in paragraph 6-8.
a Using dial indicator, manually move countershaft a Attach rear retainer (105) with bolts (104). Tor-
gear (116) back and forth using firm hand force and que bolts to 15 Ib-ft (20 Nm).
measure end play. Record end play as dimension C. f. Using dial indicator, recheck end play of counter-
f. Calculate Tc, thickness of shim (106) required, as shaft to be 0.0005-0.0040 in. (0.013-0.102 mm).
follows: g. If countershaft end play is within limits, bend
Tc = C - 0.0018 in., or tabs on rear retainer (105) up, against flats on head
Tc = C - 0.046 mm of bolts (104).
g. Remove bolts (104), rear retainer (105) and bear- h. Hook long end of spring (102) into fork, pin and
ing cup (111) temporarily installed. Select shim(s) (106) roller assembly (103) and position these parts in trans-
of thickness calculated in step f and store with bear- mission, engaging fork with groove in reverse idler
ing cup (111) until these parts are permanently gear (109).
installed.
Figure 6-6. T5 WC Reverse Fork and Idler Gear

Figure 6-5. T5 WC Countershaft Gear
6-
6-10. ASSEMBLY OF T5 WC OUTPUT SHAFT CAUTION
ASSEMBLY. On work bench, assemble output shaft Failure to assemble synchronizer sleeve and hub
assembly as follows (see figure 6-7): as they were originally could result in unsatis-
a. Install pin (100) in shaft and hub assembly (101). factory performance.
b. Be sure to assemble reverse sliding gear (98) and
hub on shaft and hub assembly (101), aligning marks c. Start reverse sliding gear (98) onto hub on shaft
made at disassembly (see figure 6-8) so that clutch and hub assembly (101) to a position that will just per-
teeth and part faces are assembled exactly as they mit installation of inserts (99). Install inserts (99) then
were originally. engage clutch teeth fully.
d. Hook one end of one spring (97) under one of the
inserts (99) and wrap around inside, under all three
inserts. Hook other end of spring under insert (see
figure 6-8).
a At other side of assembly hook remaining spring
(97) under opposite end and side of same insert (99)
where step a was started but wrap around inside in
opposite direction from step d, under all three plates.
Hook other end of spring under insert (99) (see figure
6-8).
f. Position reverse sliding gear (98) and inserts (99)
so that all inserts snap into neutral position.
g. At each end of shaft and hub assembly (101)
install 1-2 blocking ring (96), outer cone race (95) and
inner cone (94), noting the correct position and loca-
tion of these parts as shown in figure 6-7. Be sure to
align blocking ring notches with inserts (99).
h. At second speed end of shaft and hub assembly
(101), install thrust washer (93) and retaining ring (92).
Figure 6-7. T5 WC Output Shaft Assembly

Figure 6-8. Reverse Sliding Gear Assembled
6-4
6-11. ASSEMBLY OF T5 WC OUTPUT SHAFT a At other end of assembly, install sleeve (76) and
GROUP. After assembly of output shaft assembly 1st speed gear bearing as follows, according to type:
(91) as described in paragraph 6-10, proceed as follows 1. One Double-Row Bearing. Install bearing
(see figure 6-9): (75A).
a. Install spacer (90), bearing (89), 2nd speed gear 2. Two Separate Bearings. Install one bearing
(88), thrust washer (87) and snap ring (86). (75B), spacer (75C) and remaining bearing (75B).
b. Install spacer (85), bearing (84), 3rd speed gear f. Install 1st speed gear (73) and bearing cone (72).
(83) and one blocking ring (77). Use 5th driven gear (70) and suitable drift to press
c. Install 3rd-4th synchronizer assembly (78) (as bearing on cone until it is fully seated. Bearing cone
assembled in Paragraph 6-6), aligning notches in is fully seated when shaft snap ring groove is acces-
installed blocking ring (77) with synchronizer inserts. sible at outside end of 5th driven gear. Remove drift
Use a suitable drift that bears on synchronizer hub and 5th driven gear.
only.
d. Install remaining blocking ring (77), aligning
notches with inserts in installed 3rd-4th synchronizer
assembly (78).
75B
70(REF)
BLOCKING RING
3RD-4TH SYNCHRO-
NIZER ASSY
3RD SPEED GEAR
NEEDLE BEARING
BEARING CONE SPACER
1ST SPEED GEAR SNAP RING
BEARING SLEEVE 87. THRUST WASHER
ASSY 88. 2ND SPEED GEAR
75A. BEARING 89. BEARING
75B. BEARING 90. SPACER
75C. SPACER 91. OUTPUT SHAFT
76. SLEEVE ASSY
Figure 6-9. Assembly of T5 WC Output Shaft Assembly
6-5
612. INSTALLATION OF T5 WC OUTPUT c. Install thrust race (69) and thrust bearing (68) on
SHAFT GROUP. After assembly of output shaft end of output shaft (101) in transmission.
group (120) (paragraph 6-11), install as follows (see d. Rotate input shaft (65) (with pilot bearing) so
figure 6-10): that flat on its clutch tooth ring aligns with counter-
a. Tilt rear end of output shaft group (120) down shaft (116) and install in transmission, over end of out-
and install through top opening and out rear of trans- put shaft (101) using care not to dislodge bearing parts
mission case (117). Rest output shaft group on coun- previously installed.
tershaft previously installed. e. Using suitable drift, press new oil seal (61) into
b. At rear of transmission case (117), install bear- input bearing retainer (60).
ing cup (71), 5th driven gear (70) and one snap ring (56). i. Install bearing cup (63) but do not install shim(s)
6-13. ASSEMBLY AND INSTALLATION OF T5 (62) at this time.
WC INPUT SHAFT. After installing output shaft, g. Do not use sealant on input bearing retainer at
proceed as follows (see figure 6-11): this time. Align index marks made at disassembly and
a. If removed, press new bearing cone (64) onto install input bearing retainer (60). Attach with bolts
input shaft (65) to bottom out on shaft shoulder. Use (59) and torque to 15 lb-ft (20 Nm).
suitable tubular drift that contacts bearing cone inner
race only.
b. Install pilot bearing in input shaft (65) as follows,
depending on bearing type:
1. Boiler Bearing Assembly. Install bearing
assembly (66B) in end of input shaft (65).
2. Individual Bearing Rollers. Coat bearing
rollers (66A) with petrolatum and install in end of
input shaft. Install spacer (67).
Figure 6-10. Installation of T5 WC Output

Shaft Group
Figure 6-11. T5 WC Input Shaft
6-6
6-14. INSTALLATION OP T5 WC SPEED- 6-15. INSTALLATION OP T5 WC 5TH GEAR,
OMETER GEAR. On models so equipped, install SHIFT PORK AND SYNCHRONIZER. At rear of
speedometer gear as follows (see figure 6-12): transmission, install parts as follows (see figure 6-13):
a. Position clip (58) on output shaft (101) with right a Install 5th speed drive gear (55) and blocking
angle end of clip in shaft hole Start speedometer gear ring (54) on end of countershaft gear (116, figure 6-5).
(57) onto output shaft, aligning gear slot with clip. b. Attach 5th shift fork (51) to shift rail assembly
b. Using suitable tubular drift, tap speedometer (53) with roll pin (50). Install inserts (52) on 5th shift
gear (57) onto shaft until spring end of clip (58) snaps fork.
up to retain gear. c. Engage 5th shift fork (51) with previously assem-
c. Install one snap ring (56). bled (paragraph 6-7) 5th synchronizer assembly (45)
and install together in transmission noting the
following:
1. Install 5th synchronizer assembly over rear
end of countershaft gear.
2. Guide shift rail assembly (53) through reverse
fork, pin and roller assembly and spring (103 and 102,
figure 6-6) previously installed.
d. Install 5th synchronizer retainer (44) and snap
ring (43).
Figure 6-12. T5 WC Speedometer Gear
Figure 6-13. T5 WC 5th Synchronizer,

Shift Fork and Gear
6-7
6-16. INSTALLATION OF T5 WC 5-R SHIFT 6-17. ASSEMBLY AND INSTALLATION OF T5
LEVER (see figure 6-14): WC SHIFT FORKS AND CASE COVER. With case
a. Work 5-R shift lever (42) into engagement with cover on work bench, open face up, assemble shift
rollers on previously installed shift ran assembly (53, forks. Then, install on transmission. Proceed as follows
figure 6-13) and fork, pin and roller assembly (103). (see figure 6-15):
D. From outside transmission install pivot pin (40) a. Install o-ring (36) on case cover (38).
through case and 5-R shift lever (42). Torque pin to 20 b. Install inserts (32) on shift forks (30 and 31).
lb-ft(27Nm). c. Install selector plates (35) in shift forks (30 and
c. Inside transmission, attach lever to pin with
retaining ring (39). d. Start shifter shaft (29) into rear of case cover (38)
d. Install back-up switch (41). until end of shaft is flush with inside of case cover.
e. Using needle nose pliers, hook free end of previ-
ously installed spring (102, figure 6-6) on pin in trans-
mission case (117).
Figure 6-14. T5 WC 5-R Shift Lever
Figure 6-15. T5 WC Case Cover

e. Position 1-2 shift fork (31) (with inserts and selec-
tor plate) in case cover (38) and push shifter shaft (29) 34 33
just through fork. Notch in selector plate should align
with semi-circular groove in cover (see figure 6-16).
f. Align gap in interlock plate (34) with projection
on selector arm assembly (33) and install these parts
in semi- circular groove in case cover (38). Continue to
push in shifter shaft (29) until it is just through selec-
tor arm assembly (see figure 6-17).
g. Position 3-4 shift fork (30) (with inserts and selec-
tor plate) in case cover (38) so that selector plate (35)
in 3-4 shift fork is between cover and selector plate (35)
in 1-2 shift fork (31). Continue to push in shifter shaft
(29) completely through 3-4 shift fork and into cover
(see figure 6-18).
h. Align pin holes in selector arm (28) and shifter
shaft (29) and drive in selector arm pin (28) using suit-
able drift.
L Check for proper assembly of shift parts in cover:
1. Rotate shifter shaft (29) so that pin hole
through its free end is at 90 degree angle to open face
of case cover (38).
2. Check that projection on selector arm assem-
bly (33) is engaged in notch in selector plate (35)
installed in 3-4 shift fork.
j. Apply continuous 1/16 in. (1.6 mm) bead of
sealant (Neutral Cure RTV, Loctite 598) all around
transmission case (117) mounting face for case cover
(38). Center sealant bead between edges of face. Cir- Figure 6-17. Installing T5 WC Selector Arm and
cle bolt holes. Interlock Plate
k. In transmission, make sure that 1-2 syn-
chronizer, 3-4 synchronizer and 5-R shift lever are all
in neutral position.
L Position case cover (38), with assembled parts,
over transmission and gradually lower, engaging shift
forks (30 and 31) with grooves in synchronizer collars
in transmission. Lower case cover into position, mov-
ing it sideways just before it contacts transmission
case (117) as required to align bolt holes.
m. Install bolts (26 and 27) and torque to 10 lb-ft
(14 Nm).
Figure 6-18. Installing T5 WC 3rd-4th Shift Fork
Figure 6-16. Installing T5 WC 1-2 Shift Fork
6-9
6-18. INSTALLATION OF T5WC EXTENSION OR d. Apply continuous 1/16 in. (1.6 mm) bead of
ADAPTER. With case cover installed, proceed as sealant (Neutral Cure RTV, Loctite 598) all around
follows (see figure 6-19): transmission case (117) mounting face for extension
a. Install oiling funnel (25) in end of shaft of coun- (17A) or adapter (17B). Center sealant bead between
tershaft gear (116, figure 6-5). Use petrolatum to help edges of face. Circle bolt holes.
hold in place. e. Lubricate detent guide plate (18) in extension
b. Install damper sleeve (21) in offset lever (20). (17A) or adapter (17B) with lithium grease. Position
c. Make sure plug (19) and detent guide plate (18) extension or adapter so that it easily can be picked
are installed in extension (17A) or adapter (17B). up and installed on transmission.
15. ROLL PIN 23. SPRING

16. BOLT 24. OIL SEAL
17A. EXTENSION ASSY 25. OILING FUNNEL
17B. ADAPTER ASSY 29. SHIFTER SHAFT
18. DETENT GUIDE 117. CASE ASSY
PLATE
19. PLUG
20. OFFSET LEVER
21. DAMPER SLEEVE
22. BALL T5118
Figure 6-19. T5 WC Extension or Adapter
6-10
f. Position ball (22) in 3-4 position in detent guide 6-19. ADJUSTMENT OF T5 WC INPUT/OUTPUT
plate (18) (see figure 6-20). SHAFT BEARING PRELOAD. With both input
g. Insert spring (23) in offset lever (20). Use petrola- bearing retainer and extension or adapter installed as
tum to hold in place. described in preceding paragraphs, adjust input/out-
h. Position offset lever (20) (with spring) in exten- put shaft bearing preload as follows (see figure 6-21
sion (17A) or adapter (17B), engaging open end of and 6-22):
spring (23) on ball (22) and push down on offset lever a. Position transmission with input shaft end up.
to compress spring slightly. Holding offset lever with b. Remove bolts (59, figure 6-21) attaching input
one hand, pick up extension or adapter with the other bearing retainer (60) and remove bearing retainer.
and move parts into position at rear of transmission. c. Using hand pressure, press down firmly on input
Guide offset lever over end of shifter shaft (29) while shaft (65) and bearing cup (63) to ensure that power
moving extension or adapter up against rear of trans- train parts in transmission are fully seated.
mission case (117). d. Using suitable depth micrometer measure and
i. Install bolts (16) and torque to 23 lb-ft (30 Nm). record the following (see figure 6-22):
j. Align pin holes in offset lever (20) and shifter 1. Dimension A, distance from top of bearing cup
shaft (29) and drive in roll pin (15). (63) to mounting face on transmission case (117) for
input bearing retainer (60).
2. Dimension B, distance from mounting face
on input bearing retainer (60) to bearing cup contact
surface
Figure 6-20. T5 WC Ball in 3rd-4th Position

Figure 6-21. T5 WC Bearing Preload Adjustment
e. Calculate Ts> thickness of bearing preload
shim(s) (62) required, as follows:
Ts = B - A + 0.003 in., or
T s = B - A + 0.07 mm
f. Select shim(s) (62) of thickness calculated at step
e and install on end of bearing cup noting the
following:
1. Thickest shim shall be installed adjacent to
bearing cup (63). Minimum thickness of this shim shall
be 0.012 in. (0.30 mm).
2. Thinnest shim shall be installed adjacent to
bearing contact surface in input bearing retainer (60).
g. Apply continuous 1/16 in. (1.6 mm) bead of
transmission case (117) mounting face for input bear-
ing retainer (60). Center sealant bead between edges
of faca Circle bolt holes.
h. Align index marks made at disassembly and
install input bearing retainer (60). Attach with bolts
(59) and torque to 15 lb-ft (20 Nm).
6-20. INSTALLATION OF T5 WC EXTERNAL
COMPONENTS AND CONTROL LEVER AND
HOUSING ASSEMBLY. Complete transmission
assembly as follows (see figure 6-23):
a. Install o-rings (14) on speedo adapter (10). Insert
oil seal (13) and speedo driving gear (12), then install
pin (11).
b. Install speedo adapter (10), with assembled
parts, in transmission and attach with screw (9).
c. If used, install harness retainer (8), pin (7) and
neutral switch (6).
d. Install vent and o-ring assembly (5A) or breather
(5B).
e. Install control lever and housing assembly (3A,
3B or 3C):
65 1. Install boot (4) if replaced.
2. Apply continuous 1/16 in. (1.6 mm) bead of
extension (17A) or adapter (17B) mounting face for
control lever and housing assembly (3A, 3B or 3C).
Center sealant bead between edges of faca Circle bolt
holes.
3. Position control lever and housing assembly
(3A, 3B or 3C) on extension (17A) or adapter (17B)
engaging inside end of lever in damper sleeve (21,
figure 6-19) installed in offset lever (20, figure 6-19).
4. Install screws (2). If control lever and housing
assembly (3C) is used, also install screws (2A). Torque
all screws to 13 lb-ft (17 Nm).
f. Install fill and drain plugs (1) and torque to
20 lb-ft (27 Nm).
60. INPUT BEARING

RETAINER
63. BEARING CUP
65. INPUT SHAFT
117. CASE ASSY
TS121
Figure 6-22. T5 WC Bearing Preload

Measurements
6-12
1.PLUG 3C. CONTROL LEVER AND 7. PIN 12. SPEEDO DRIVING
2. SCREW HOUSING ASSY 8. HARNESS GEAR
2A. SCREW 4. BOOT RETAINER 13. OIL SEAL
3A. CONTROL LEVER AND 5A. VENT AND O-RING 9. ADAPTER SCREW 14. O-RING
HOUSING ASSY ASSY 10. SPEEDO ADAPTER 16. BOLT
3B. CONTROL LEVER AND 5B. BREATHER 11. ROLL PIN 17A. EXTENSION ASSY
HOUSING ASSY 6. SWITCH ASSY 17B. ADAPTER ASSY 15122
Figure 6-23. T5 WC Control Lever Housing and External Components
6-13
Table 6-1. T5 WC Transmission Torque Values
PART (FIG. 5-1
INDEX NO.) TORQUE IN LB-FT TORQUE IN Nm
Drain plug (1) 20 27
Screw (2 & 2A) 13 17
Bolt (16) 23 30
Bolt (26 & 27) 10 14
Pivot pin (40) 20 27
Bolt (59) 15 20
Bolt (104) 15 20
6-14
Section 7
T5 NWC Assembly
7-1. GENERAL INFORMATION

7-2. During assembly, refer to the illustrations speci-
fied in the text. In addition, an exploded view or the
complete assembly can be seen on figure 5-2 in Sec-
tion 5, Cleaning, Inspection, Repair or Replacement.
Note the following during assembly:
a. When a torque value is specified, use a torque
wrench to tighten the threaded part. Torque values are
specified in the text and also in Table 7-1 at the end
of this section.
b. Coat small parts with petrolatum to help hold
them in place during assembly. 75. SYNCHRONIZER
7-3. LUBRICATION DURING ASSEMBLY. Lubri- SPRING
cate all internal parts, not coated with petrolatum, 76. SYNCHRONIZER
with approved transmission lubricant (refer to para- SLEEVE
graph 2-4) just prior to assembly. This will ease assem-
bly and provide initial lubrication. 77. INSERT
a. O-rings and shaft seal lips may be damaged dur- 78. SYNCHRONIZER
ing assembly if not lubricated. HUB
b. Make sure all bearings (refer to paragraph 7-5) TS123
are thoroughly lubricated before assembly. Running
bearings dry, even for a brief period, will cause Figure 7-1. T5 NWC 3rd-4th
damage. Synchronizer Assembly
7-4. T5 NWC TRANSMISSION ASSEMBLY
PROCEDURES
7-5. T5 NWC BEARING LUBRICATION.Before
assembly, make sure that each of the following anti-
friction bearings is thoroughly lubricated (refer to
paragraph 7-3 and see figure 5-2):
Bearing (39)
Bearing cone (61)
Bearing rollers (63)
Thrust bearing (64)
Bearing cone (68)
Needle Dealing (71)
Bearing (101)
Bearing (103)
7-6. ASSEMBLY OF T5 NWC 3RD-4TH SYN-
CHRONIZER ASSEMBLY (see figure 7-1). Be sure
to assemble sleeve (78) and hub (78) aligning marks
made at disassembly (see figure 7-2) so that clutch
teeth and part faces are assembled exactly as they
were originally. Assemble as follows:
CAUTION
NOTE
separate parts. Skip this paragraph and install Figure 7-2. T5 NWC 3rd-4th
Synchronizer Assembled
b. Hook one end of one spring (75) under one of the
a. Start sleeve (76) onto hub (78) to a position that inserts (77) and wrap around inside, under all three
will just permit installation of inserts (77). Install inserts. Hook other end of spring under insert (see
inserts (77) then engage clutch teeth fully. figure 7-2).
7-1
c Invert assembly. Hook remaining spring (75)
under opposite end and side of same insert (77) where
step b was started but wrap around inside in opposite
direction from step b, under all three plates. Hook
other end of spring under insert (77) (see figure 7-2).
d. Position sleeve (76) and inserts (77) so that all
e. Set 3rd-4th synchronizer aside for later installa-
tion in transmission.
7-7. ASSEMBLY OF T5 NWC 5TH SYNCHRO-
disassembly so that clutch teeth and part faces are
assembled exactly as they were originally. Assemble
as follows:
42. RETAINER 45. INSERT

43. SYNCHRONIZER 46. SYNCHRONIZER
SPRING HUB
44. SYNCHRONIZER
SLEEVE T5126
42. RETAINER Figure 7-4. T5 NWC 5th Synchronizer Assembled

43. SYNCHRONIZER
SPRING
44. SYNCHRONIZER
SLEEVE
45. INSERT
46, SYNCHRONIZER
HUB
Figure 7-3. T5 NWC 5th Synchronizer Assembly
CAUTION
NOTE
separate parts. Skip this paragraph and install
a. Start sleeve (44) onto hub (46) to a position that
will just permit installation of inserts (45). Install
b. Install springs (43) so that tangs at each end of
both springs are in the same insert (45) (see figure 7-4).
c. Position sleeve (44) and inserts (45) so that all
d. Install retainer (42). 101. BEARING 105. COUNTERSHAFT
a Set 5th synchronizer aside for later installation.
102. SPACER GEAR -
7-8. ASSEMBLY AND INSTALLATION OF T5 103. BEARING 106. CASE ASSY
NWC COUNTERSHAFT GEAR (see figure 7-5): 104. THRUST WASHER T5127
a. If replaced, press bearing (103) into transmission
case (106) using suitable drift so that bearing is flush Figure 7-5. T5 NWC Countershaft Gear
with outside surface of case.
7-2
b. Install thrust washer (104) on countershaft gear a. Start reverse idler shaft (98) in through rear open-
(105). ing in transmission case (106) with pin hole in shaft
c. Install countershaft gear (105), with thrust pointing up toward top case opening.
washer (104), through top opening of transmission b. Position o-ring (100) and reverse idler gear assem-
case (106), rear end first. Extend rear end of counter- bly (99) in transmission case (106) and continue to
shaft gear through rear case opening enough to seat push reverse idler shaft (98) into case, through gear,
front end in bearing (103). o-ring and boss inside case.
d. Install spacer (102) and bearing (101) over end c. Install roll pin (97). Using suitable drift, tap pin
of countershaft gear (105) and into bore in transmis- into reverse idler shaft (98) until pin is centrally
sion case (106). located in shaft.
7-9. INSTALLATION OF T5 NWC REVERSE d. Install thrust washer (96). Install snap ring (95)
FORK AND IDLER GEAR. With assembly com- in groove in countershaft gear (105).
pleted as described through paragraph 7-8, proceed as a Depending on construction used, install parts by
follows (see figure 7-6): one of the following methods:
1. Hook spring long end of spring (92A) into fork,
pin and roller assembly (94 A) ana position these parts
m transmission, engaging fork with groove in reverse
92B idler gear.
2. Install hook (93) in fork, pin and roller assem-
bly (94B) and spring (92B) on hook. Position these
parts in transmission, engaging fork with groove in
reverse idler gear.
7-10. ASSEMBLY OF T5 NWC OUTPUT SHAFT
ASSEMBLY. On work bench, assemble output shaft
94A
88 85
87. INSERT
84. 1-2 BLOCKING 88. PIN
RING 89. BALL
85. SPRING 90. SPRING
86. REVERSE SLIDING 91. SHAFT AND HUB
GEAR ASSY T5V
95.
SNAP RING
Figure 7-7. T5 NWC Output Shaft Assembly
96.
THRUST WASHER
92A. SPRING ROLL PIN
97
92B. SPRING REVERSE IDLER
98
93. HOOK SHAFT
94A. FORK, PIN AND 99 REVERSE IDLER
ROLLER ASSY GEAR
94B. FORK, PIN AND 100 O-RING
ROLLER ASSY 106 CASE ASSY T5128
Figure 7-6. T5 NWC Reverse Fork and Idler Gear
7-3
a. Depending on which is used, install pin (88), or 7-11. ASSEMBLY OF T5 NWC OUTPUT SHAFT
spring (90) and ball (89) in shaft and hub assembly (91) GROUP. After assembly of output shaft assembly
and hold in place (83) as described in paragraph 7-10, proceed as follows
b. Be sure to assemble reverse sliding gear (86) and (see figure 7-9):
hub on shaft and hub assembly (91) aligning marks a. Install 2nd speed gear (82), thrust washer (81)
made at disassembly (see figure 7-8) so that clutch and snap ring (80).
teeth and part faces are assembled exactly as they
were originally. b. Install 3rd speed gear (79) and one blocking ring
(73).
CAUTION c Install 3rd-4th synchronizer assembly (74) (as
Failure to assemble synchronizer gear and hub assembled in paragraph 7-6), aligning notches in
as they were originally could result in unsatis- installed blocking ring (73) with synchronizer inserts.
factory performance. Use a suitable drift that bears on synchronizer hub
only.
c. Start reverse sliding gear (86) onto hub on shaft d. Install remaining blocking ring (73), aligning
and hub assembly (91) to a position that will just per- notches with inserts in installed 3rd-4th synchronizer
mit installation of inserts (87). Install inserts (87) then assembly (74).
engage clutch teeth fully. e. At other end of assembly, install thrust race (72)
a. Hook one end of one spring (85) under one of the and needle bearing (71).
inserts (87) and wrap around inside, under all three f. Install 1st speed gear (70), thrust washer (69) and
inserts. Hook other end of spring under insert (see bearing cone (68). Use 5th driven gear (66) and suit-
figure 7-8). able drift to press bearing on cone until it is fully
e. At other side of assembly hook remaining spring seated. Bearing cone is fully seated when shaft snap
(85) under opposite end and side of same insert (87) ring groove is accessible at outside end of 5 th driven
where step d was started but wrap around inside in gear. Remove drift and 5th driven gear.
opposite direction from step d, under all three plates. 7-12. INSTALLATION OF T5 NWC OUTPUT
Hook other end of spring under insert (99) (see figure SHAFT GROUP. After assembly of output shaft
7-8). group (120) (paragraph 7-11), install as follows (see
f. Position reverse sliding gear (86) and inserts (87) figure 7-10):
so that all inserts snap into neutral position. a. Tilt rear end of output shaft group (120) down
g. At each end of shaft and hub assembly (91) and install through top opening and out rear of trans-
install 1-2 blocking ring (84). Be sure to align block- mission case (106). Rest output shaft group on coun-
ing ring notches with inserts (87). tershaft previously installed.
b. At rear of transmission case (106), install bear-
ing cup (67), 5th driven gear (66) and one snap ring (53).
Figure 7-8. T5 NWC Reverse Sliding

Gear Assembled
7-4
66 (REF)
68. BEARING CONE

69. THRUST WASHER
70. 1ST SPEED GEAR
71. NEEDLE BEARING
72. THRUST RACE
73. BLOCKING RING
74. 3RD-4TH SYNCHRO-
NIZER ASSY
79. 3RD SPEED GEAR
80. SNAP RING
•81. THRUST WASHER
82. 2ND SPEED GEAR
83. OUTPUT SHAFT
ASSY
T5131
Figure 7-9. Assembly of T5 NWC Output Shaft Group
67. BEARING CUP

106. CASE ASSY
53. SNAP RING 120. OUTPUT SHAFT
66. 5TH DRIVEN GEAR GROUP
TS132
T5132
Figure 7-10. Installation of T5 NWC

Output Shaft Group
7-5
7-13. ASSEMBLY AND INSTALLATION OF T5 7-14. INSTALLATION OF T5 NWC SPEEDOME-
NWC INPUT SHAFT. After installing output shaft, TER GEAR. On models so equipped, install speedom-
proceed as follows (see figure 7-11): eter gear as follows (see figure 7-12):
a. If removed, press new bearing cone (61) onto a. If speedometer gear is retained by a clip, proceed
input shaft (62) to Dottom out on shaft shoulder. Use as follows:
suitable tubular drift that contacts bearing cone inner 1. Position clip (55A) on output shaft (91) with
race only. right angle end of clip in shaft hole Start speedome-
b. Coat bearing rollers (63) with petrolatum and ter gear (54) onto output shaft, aligning gear slot with
install in end of input shaft. clip.
c. Install thrust race (65) and thrust bearing (64) on 2. Using suitable tubular drift, tap speedometer
end of output shaft (91) in transmission. gear (54) onto shaft (91) until spring end of clip (55A)
d. Rotate input shaft (62) (with bearing rollers) so snaps up to retain gear.
that flat on its clutch tooth ring aligns with counter- b. If speedometer gear is retained by a ball, proceed
shaft (105) and install in transmission, over end of out- as follows:
put shaft (91) using care not to dislodge bearing parts 1. Position ball (55B) in hole in output shaft (91).
previously installed. 2. Slide speedometer gear (54) onto output shaft,
a Using suitable drift, press new oil seal (58) into open end of notch in gear first and aligned with ball,
input bearing retainer (57). until gear is seated on ball.
1. Install bearing cup (60) but do not install shim(s) c Install remaining snap ring (53).
(59) at this time.
g. Do not use sealant on input bearing retainer at
tins time Align index marks made at disassembly and
(56) and torque to 15 Ib-ft (20 Nm).
Figure 7-12. T5 NWC Speedometer Gear
Figure 7-11. T5 NWC Input Shaft
7-6
7-15. INSTALLATION OF T5 NWC 5TH GEAR, 7-16. INSTALLATION OF T5 NWC 5-R SHIFT
SHIFT FORK AND SYNCHRONIZER. At rear of LEVER (see figure 7-14):
transmission case (106), install parts as follows (see
figure 7-13): NOTE
a. Install 5th speed drive gear (52) and blocking On units with fork, pin and roller assembly (94B,
ring (51) on end of countershaft gear (105, figure 7-5). figure 7-6), 5-R shift lever is permanently
b. Attach 5th shift fork (48) to shift rail assembly attached to the fork. In the following step, it is
(50) with roll pin (47). Install inserts (49) on 5th shift necessary to engage lever with roller on shift rail
fork. (50, figure 7-13) only.
c. Engage 5th shift fork (48) with previously assem-
bled (paragraph 7-7) 5th synchronizer assembly (41) a. Work 5-R shift lever (36) into engagement with
and install together in transmission noting the rollers on previously installed shift rail assembly (50,
following: figure 7-13) and fork, pin and roller assembly (94A,
1. Install 5th synchronizer assembly (41) over figure 7-6).
rear end of countershaft gear (105). b. From outside transmission install pivot pin (34)
2. Guide shift rail assembly (50) through reverse through case and 5-R shift lever (36 or part of 94B,
fork, pin and roller assembly (94A or 94B, figure 7-6) figure 7-6). Torque pin to 20 lb-ft (27 Nm).
and, when used, spring (92A, figure 7-6) previously c Inside transmission, attach lever to pin with
installed. retaining ring (33).
d. Install thrust race (40), bearing (39), and thrust d. Install back-up switch (35).
race (38). Retain these parts by installing snap ring a Using needle nose pliers, hook free end of previ-
(37). ously installed spring (92A or 92B, figure 7-6) on pin
in transmission case (106).
Figure 7-14. T5 NWC 5-R Shift Lever
Figure 7-13. T5 NWC 5th Gear, Shift

Fork and Synchronizer
7-7
7-17. ASSEMBLY AND INSTALLATION OF T5 a. Install o-ring (30) on case cover (32).
NWC SHIFT FORKS AND CASE COVER. With b. Install inserts (26) on shift forks (24 and 25).
case cover on work bench, open face up, assemble shift a Install selector plates (29) in shift forks (24 and
forks. Then, install on transmission. Proceed as follows 25).
(see figure 7-15): d. Start shifter shaft (23) into rear of case cover (32)
until end of shaft is flush with inside of case cover.
e. Position 1-2 shift fork (25) (with inserts and selec-
tor plate) in case cover (32) and push shifter shaft (23)
just through fork. Notch in selector plate should align
with semi-circular groove in cover (see figure 7-16).
23. SHIFTER SHAFT 29. SELECTOR PLATE

25. 1-2 SHIFT FORK 32. CASE COVER
26. INSERT T5138
Figure 7-16. Installing T5 NWC 1-2 Shift Fork
f. Align gap in interlock plate (28) with projection

on selector arm assembly (27) and install these parts
in semi-circular groove in case cover (32). Continue to
push in shifter shaft (23) until it is just through selec-
tor arm assembly (see figure 7-17).
BOLT 27. SELECTOR ARM

BOLT ASSY
SELECTOR ARM 28. INTERLOCK PLATE
PIN 29. SELECTOR PLATE
SHIFTER SHAFT 30. O-RING
3-4 SHIFT FORK 31. PLUG
1-2 SHIFT FORK 32. CASE COVER
26. INSERT 106. CASE ASSY TS137
Figure 7-15. T5 NWC Case Cover
23. SHIFTER SHAFT

25. 1-2 SHIFT FORK
27. SELECTOR ARM
ASSY
28. INTERLOCK PLATE
29. SELECTOR PLATE
T5139
Figure 7-17. Installing T5 NWC Selector

Arm and Interlock Plate
7-8
g. Position 3-4 shift fork (24) (with inserts and selec- j. Apply continuous 1/16 in. (1.6 mm) bead of
tor plate) in case cover (32) so that selector plate (29) sealant (Neutral Cure RTV, Loctite 598) all around
in 3-4 shift fork is between cover and selector plate (29) transmission case (106) mounting face for case cover
in 1-2 shift fork (25). Continue to push in shifter shaft (32). Center sealant bead between edges of face. Cir-
(23) completely through 3-4 shift fork and into cover cle bolt holes.
(see figure 7-18). k. In transmission, make sure that 1-2 syn-
chronizer, 3-4 synchronizer and 5-R shift lever are all
in neutral position.
1. Position case cover (32), with assembled parts,
over transmission and gradually lower, engaging shift
forks (24 and 25) with grooves in synchronizer collars
in transmission. Lower case cover into position, mov-
ing it sideways just before it contacts transmission
case (106) as required to align bolt holes.
m. Install bolts (20 and 21) and torque to 10 Ib-ft
(14 Nm).
7-18. INSTALLATION OF T5 NWC EXTENSION
OR ADAPTER. With case cover installed, proceed as
follows (see figure 7-19):
a. Install oiling funnel (19) in end of shaft of coun-
tershaft gear (105, figure 7-5). Use petrolatum to help
hold in place.
b. Install damper sleeve (15) in offset lever (14).
c. Make sure plug (13) and detent guide plate (12)
are installed in extension (11 A) or adapter (11B).
d. Apply continuous 1/16 in. (1.6 mm) bead of
transmission case (106) mounting face for extension
(11A) or adapter (11B). Center sealant bead between
edges of face. Circle bolt holes.
Figure 7-18. Installing T5 NWC 3rd-4th Shift Fork
h. Align pin holes in selector arm (27) and shifter

shaft (23) and drive in selector arm pin (22) using suit-
able drift.
L Check for proper assembly of shift parts in cover
1. Rotate shifter shaft (23) so that pin hole
through its free end is at 90 degree angle to open face
of case cover (32).
2. Check that projection on selector arm assem-
bly (27) is engaged in notch in selector plate (29)
installed in 3-4 snift fork.
7-9
9. ROLL PIN
10. BOLT
11B. ADAPTER ASSY
12. DETENT GUIDE
PLATE
13. PLUG
14. OFFSET LEVER
15. DAMPER SLEEVE
16. BALL
17. SPRING
18. OIL SEAL
19. OILING FUNNEL
23. SHIFTER SHAFT
106. CASE ASSY
TS141
Figure 7-19. T5 NWC Extension or Adapter
7-10
e. Lubricate detent guide plate (12) in extension 7-19. ADJUSTMENT OF T5 NWC INPUT/OUT-
(11A) or adapter (11B) with lithium grease. Position PUT SHAFT BEARING PRELOAD. With both
extension or adapter so that it easily can be picked input bearing retainer and extension or adapter
up and installed on transmission. installed as described in preceding paragraphs, adjust
f. Position ball (16) in 3-4 position in detent guide input/output shaft bearing preload as follows (see
plate (12) (see figure 7-20). figure 7-21 and 7-22):
g. Insert spring (17) in offset lever (14). Use petrola- a. Position transmission with input shaft end up.
tum to hold in place. b. Remove bolts (56, figure 7-21) attaching input
h. Position onset lever (14) (with spring) in exten- bearing retainer (57) and remove bearing retainer.
sion (11A) or adapter (11B), engaging open end of c Using hand pressure, press down firmly on input
spring (17) on ball (16) and push down on offset lever shaft (62) and bearing cup (60) to ensure that power
to compress spring slightly. Holding offset lever with train parts in transmission are fully seated.
one hand, pick up extension or adapter with the other d. Using suitable depth micrometer measure and
and move parts into position at rear of transmission. record the following (see figure 7-22):
Guide offset lever over end of shifter shaft (23) while
moving extension or adapter up against rear of trans-
mission case (106).
i. Install bolts (10) and torque to 23 lb-ft (30 Nm).
j. Align pin holes in offset lever (14) and shifter
shaft (3) and drive in roll pin (9).
Figure 7-21. T5 NWC Bearing Preload Adjustment

12. DETENT GUIDE
PLATE
14. OFFSET LEVER
16. BALL
17. SPRING T5142
Figure 7-20. T5 NWC Ball in 3rd-4th Position
7-11
1. Dimension A, distance from top of bearing cup
(60) to mounting face on transmission case (106) for
input bearing retainer (57).
2. Dimension B, distance from mounting face
on input bearing retainer (57) to bearing cup contact
surface.
e. Calculate T s , thickness of bearing preload
shim(s) (59) required, as follows:
Ts = B - A + 0.003 in., or
T8 = B - A + 0.07 mm
f. Select shim(s) (59) of thickness calculated at
step e and install on end of bearing cup noting the
following:
1. Thickest shim shall be installed adjacent to
bearing cup (60). Minimum thickness of this shim shall
be 0.012 in. (0.30 mm).
2. Thinnest shim shall be installed adjacent to
bearing contact surface in input bearing retainer (57).
g. Apply continuous 1/16 in. (1.6 mm) bead of
transmission case (106) mounting face for input bear-
ing retainer (57). Center sealant Dead between edges
of face. Circle bolt holes.
h. Align index marks made at disassembly and
(56) and torque to 15 lb-ft (20 Nm).
7-20. INSTALLATION OF T5 NWC EXTERNAL
COMPONENTS AND CONTROL LEVER AND
HOUSING ASSEMBLY. Complete transmission
a. If used, install wire retainer (8), pin (7) and neu-
tral switch (6).
b. Install vent and o-ring assembly (5A) or breather
(5B).
c. Install control lever and housing assembly (3A
or 3B):
1. Install boot (4) if replaced.
2. Apply continuous 1/16 in. (1.6 mm) bead of
extension (11 A) or adapter (11B) mounting face for
control lever and housing assembly (3A or 3B). Center
sealant bead between edges of face. Circle bolt holes.
3. Position control lever and housing assembly
(3A or 3B) on extension (11A) or adapter (11B) engag-
ing inside end of lever in damper sleeve (15, figure
7-19) installed in offset lever (14, figure 7-19).
4. Install screws (2) and torque to 13 lb-ft (17 Nm).
d. Install fill and drain plugs (1) and torque to 20
lb-ft (27 Nm).
57. INPUT BEARING

RETAINER
60. BEARING CUP
62. INPUT SHAFT
106. CASE ASSY
T5144
Figure 7-22. T5 NWC Bearing

Preload Measurements
7-12
1. PLUG
2. SCREW
3A. CONTROL LEVER AND
HOUSING ASSY
3B. CONTROL LEVER AND
HOUSING ASSY
4. BOOT
5A. VENT AND O-RING
ASSY
5B. BREATHER
6. SWITCH ASSY
7. PIN
8. WIRE RETAINER
11A. EXTENSION ASSY
11B. ADAPTER ASSY
Figure 7-28. T5 NWC External Components and Control Lever Housing
7-13
Table 7-1. T5 NWC Transmission Torque Values
PART (FIG. 5-1
INDEX NO.) TORQUE IN LB-FT TORQUE IN Nm
Drain plug (1) 20 27
Screw (2) 13 17
Bolt (10) 23 30
Bolt (20 & 21) 10 14
Pivot pin (34) 20 27
Bolt (56) 15 20
7-14

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IMPORTANT SAFETY NOTICE

NOTES, CAUTIONS, AND WARNINGS

• Always wear safety glasses for eye protection.

• Do not smoke while working on the vehicle.

Table 1-2. Basic Differences Between T5 WC and NWC Classes

Figure 2-2. Transmission

Figure 2-3. Front Propeller Shaft Figure 2-4. Transfer Case

3-1. GENERAL INFORMATION 3-6. T5 WC TRANSMISSION DISASSEMBLY

Table 3-1. T5 WC Transmissions

Figure 3-1. T5 WC Control Lever Housing and External Components

15. ROLL PIN 23. SPRING

Figure 3-2. T5 WC Extension or Adapter

Figure 3-3. T5 WC Case Cover

Figure 3-4. T5 WC 5-R Shift Lever

43. SNAP RING 52. INSERT

Figure 3-7. T5 WC Input Shaft

Figure 3-9. Disassembly of T5 WC Output Shaft Group

Figure 3-11. T5 WC Reverse Fork and Idler Gear

Figure 3-10. T5 WC Output Shaft Assembly

46. SYNCHRONIZER 48. INSERT

Figure 3-13. T5 WC 5th Synchronizer Assembly

111. BEARING CUP 79. SYNCHRONIZER 81. INSERT

Figure 3-12. T5 WC Countershaft Gear

4-1. GENERAL INFORMATION 4-6. T5 NWC TRANSMISSION

Table 4-1. T5 NWC Transmissions

Figure 4-1. T5 NWC Control Lever Housing & External Components

Figure 4-2. T5 NWC Extension or Adapter

On some units, 5-R shift lever is permanently

Figure 4-6. T5 NWC Speedometer Gear

Figure 4-5. T5 NWC 5th Synchronizer,

Figure 4-7. T5 NWC Input Shaft

Figure 4-9. Disassembly of T5 NWC Output Shaft Group

Figure 4-10. T5 NWC Output Shaft Assembly

Figure 4-11. T5 NWC Reverse Fork and Idler Gear

Figure 4-14. T5 NWC 3rd-4th Synchronizer Assembly

101. BEARING 105. COUNTERSHAFT

Figure 4-12. T5 NWC Countershaft Gear

5-1. CLEANING 5-4. LUBRICATING BEARINGS. Immediately

• Used on specific models

•Used on specific models

Indentation: Displacement of material caused by

DESCRIPTION ACCEPT REJECT

LOW CONTACT PATTERN

Figure 54. Gear Tooth Contact Patterns

Chipped or broken tabs for inserts Replace damaged fork

Check friction surfaces for excessive Replace worn or damaged parts

Make sure bearing cone or bearing is Replace bearing cones or bearings

Check bearing journals Replace if scored or damaged

Check bearing journals Replace if scored or damaged

Check splines per paragraph 5-9 Paragraph 5-9

CORNER CHIP WITHIN

Figure 5-5. Gear Tooth Chips

6-1. GENERAL INFORMATION NOTE

Figure 6-3. T5 WC 5th Synchronizer Assembly

Figure 6-2. T5 WC 3rd-4th Synchronizer

Figure 6-6. T5 WC Reverse Fork and Idler Gear

Figure 6-7. T5 WC Output Shaft Assembly

Figure 6-9. Assembly of T5 WC Output Shaft Assembly

Figure 6-10. Installation of T5 WC Output

Figure 6-12. T5 WC Speedometer Gear