MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. B007VQW

      Remove the manual transmission filler plug and gasket from the manual transmission case.

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. B007T7C

      Remove the manual transmission drain plug and gasket from the manual transmission case.

  3. REMOVE CLUTCH HOUSING


    1. B007ORI

      Remove the 9 bolts.

    2. B007SZI

      Using a plastic-faced hammer, remove the clutch housing from the manual transmission case.

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. B007U5QE01

      Using SST, remove the back up light switch assembly and gasket from the manual transmission case.

      SST
      09817-16011

  5. REMOVE SPEEDOMETER SENSOR


    1. Remove the bolt and speedometer sensor from the extension (MTM) housing sub-assembly.

    2. Remove the O-ring from the speedometer sensor.

  6. REMOVE EXTENSION HOUSING(MTM) COVER


    1. B007PQI

      Remove the 6 bolts, extension housing (MTM) cover and gasket.

  7. REMOVE EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. Using a brass bar and a hammer, remove the extension housing dust (MTM) deflector from the extension (MTM) housing sub-assembly.

  8. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. B007W1F

      Remove the 6 bolts.

    2. B007R51

      Using a plastic-faced hammer, remove the shift lever shaft housing sub-assembly.

  9. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. B007S03

      Remove the 10 bolts.

    2. Using a plastic-faced hammer, remove the extension (MTM) housing sub-assembly.

  10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE


    1. Remove the bolt and extension housing oil receiver pipe from the extension (MTM) housing sub-assembly.

  11. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. B007OBQ

      Remove the No. 1 extension housing oil receiver pipe.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. B007TEB

      Using a screwdriver and hammer, remove the manual transmission extension housing oil seal from the extension (MTM) housing sub-assembly.

  13. REMOVE FRONT BEARING RETAINER (MTM)


    1. B007VQZ

      Remove the 8 bolts.

    2. B007U76

      Using a brass bar and hammer, remove the front bearing retainer (MTM) from the manual transmission case.

  14. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL


    1. B007SPDE01

      Fix the front bearing retainer (MTM) in a vise in aluminum plate.

    2. Using SST, remove the front transmission bearing retainer oil seal.

      SST
      09308-00010

  15. REMOVE FRONT BEARING SHAFT SNAP RING


    1. B007Q7K

      Using a snap ring expander, remove the front bearing shaft snap ring from the manual transmission case.

  16. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING


    1. B007RW6

      Using a snap ring expander, remove the No. 1 counter gear front bearing snap ring from the manual transmission case.

  17. REMOVE MANUAL TRANSMISSION CASE


    1. B007SRZ

      Using a brass bar and hammer, remove the manual transmission case from the intermediate plate.

  18. REMOVE TRANSMISSION MAGNET


    1. B007TEO

      Remove the transmission magnet from the intermediate plate.

  19. FIX INTERMEDIATE PLATE


    1. B007Q9N

      Fix the intermediate plate in a vise in between aluminum plates.

  20. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. B007TDD

      Using a T40 "TORX" socket wrench, remove the No. 1 shift detent ball spring seat from the intermediate plate.

    2. B007SC5

      Using a magnet hand, remove the compression spring and shift detent ball from the intermediate plate.

    3. B007T3W

      Using a T40 "TORX" socket wrench, remove the 2 No. 1 shift detent ball spring seats from the intermediate plate.

    4. B007U5S

      Using a magnet hand, remove the 2 compression springs and 2 shift detent balls from the intermediate plate.

  21. REMOVE SHIFT FORK SHAFT STOPPER


    1. B007QSA

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 1 gear shift fork shaft.

    2. Remove the shift fork shaft stopper from the No. 1 gear shift fork shaft.

  22. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. B007TH1

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 1 gear shift fork shaft.

      Note

      Use a piece of cloth to prevent the snap ring from flying off.

    2. B007SXA

      Remove the bolt from the No. 1 gear shift fork.

    3. B007PXH

      Remove the No. 1 gear shift fork shaft from the intermediate plate.

    4. B007RO2

      Using a magnet hand, remove the No. 1 shift interlock roller and shift interlock pin from the intermediate plate.

  23. REMOVE SHIFT FORK SHAFT STOPPER


    1. B007UM9

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 2 gear shift fork shaft.

    2. Remove the shift fork shaft stopper from the No. 2 gear shift fork shaft.

  24. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. B007SDE

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Note

      Use a piece of cloth to prevent the snap ring from flying off.

    2. B007QYD

      Remove the bolt from the No. 2 gear shift fork.

    3. B007RZA

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 2 gear shift fork shaft.

    4. B007TPW

      Remove the No. 2 gear shift fork shaft and No. 2 gear shift head.

    5. B007UIC

      Remove the No. 1 gear shift fork and No. 2 gear shift fork from the output shaft assembly.

    6. B007UX7

      Using a magnet hand, remove the No. 1 shift interlock roller from the intermediate plate.

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. B007P4L

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the reverse shift fork shaft.

    2. B007UN5

      Using a magnet hand, remove the straight pin from the reverse shift fork.

    3. B007RWR

      Using 2 screwdrivers and a hammer, remove the snap ring from the reverse shift fork shaft.

      Note

      Use a piece of cloth to prevent the snap ring from flying off.

    4. B007RRD

      Remove the reverse shift fork shaft and No. 3 gear shift fork.

  26. REMOVE REVERSE SHIFT FORK


    1. B007QU9

      Remove the reverse shift fork from the reverse shift arm.

  27. REMOVE REVERSE SHIFT ARM BRACKET


    1. B007VWM

      Remove the torsion spring from the reverse shift arm bracket.

    2. B007R9M

      Remove the 2 bolts and reverse shift arm bracket from the intermediate plate.

    3. B007PVO

      Using a screwdriver, pry out the snap ring from the reverse shift arm bracket.

    4. B007QF5

      Remove the reverse shift arm from the reverse shift arm bracket.

  28. REMOVE SPEEDOMETER DRIVE (MTM) GEAR


    1. B007VZI

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive (MTM) gear and steel ball.

    3. Using a magnet hand, remove the steel ball.

    4. Using snap ring expander, remove the snap ring.

  29. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. B007P7K

      Using 2 screwdrivers and a hammer, remove the output shaft bearing shaft snap ring from the output shaft assembly.

  30. REMOVE OUTPUT SHAFT REAR BEARING


    1. B007SJ8E04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the output shaft rear bearing and output shaft spacer from the output shaft assembly.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

  31. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. B007THQ

      Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)

  32. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. B007W1M

      Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.

      Standard clearance
      0.015 to 0.068 mm (0.0059 to 0.0027 in.)

      If the clearance is not within the specified values, replace the counter 5th gear bearing with a new one.

  33. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. B007QB7

      Using 2 screwdrivers and a hammer, remove the counter gear rear shaft snap ring from the counter gear.

  34. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. B007V44

      Remove the No. 3 transmission hub sleeve from the counter shaft 5th gear.

  35. REMOVE COUNTER SHAFT 5TH GEAR


    1. B007P4HE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the counter shaft 5th gear together with the counter 5th gear bearing, 2 No. 3 synchromesh shifting keys, No. 3 synchromesh shifting key spring, outer No. 3 synchronizer ring and No. 5 gear spline piece from the counter gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )

  36. REMOVE NO. 5 GEAR SPLINE PIECE


    1. B007SSD

      Remove the No. 5 gear spline piece from the counter shaft 5th gear.

  37. REMOVE OUTER NO. 3 SYNCHRONIZER RING


    1. Remove the outer No. 3 synchronizer ring from the counter shaft 5th gear.

  38. REMOVE COUNTER 5TH GEAR BEARING


    1. B007TMG

      Remove the counter 5th gear bearing from the counter shaft 5th gear.

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING


    1. B007PRM

      Using a snap ring expander, remove the shaft snap ring.

    2. B007RFY

      Remove the No. 3 synchromesh shifting key spring and 2 No. 3 synchromesh shifting keys from the counter shaft 5th gear.

  40. REMOVE 5TH GEAR THRUST WASHER


    1. B007QDO

      Remove the 5th gear thrust washer from the counter gear.

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. B007VH9

      Remove the 5th gear thrust washer pin from the counter gear.

  42. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. B007SVL

      Remove the 4 bolts and output shaft rear bearing (MTM) retainer from the intermediate plate.

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. B007RIFE03

      Pull out the reverse idler gear shaft to the rear side and remove the reverse idler gear sub-assembly from the intermediate plate.

  44. REMOVE COUNTER SHAFT CENTER BEARING


    1. B007P0Z

      Using a snap ring expander, remove the snap ring.

    2. B007TYXE01

      Using SST, remove the counter shaft center bearing from the intermediate plate.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )

      Tech Tips

      Remove the bearing while tapping the tip of the counter gear so that the counter gear assembly is not pushed forward into the side wall of the output shaft assembly gear.

  45. REMOVE COUNTER GEAR


    1. B007SPC

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT ASSEMBLY


    1. B007RNU

      Remove the input shaft assembly and No. 2 synchronizer ring from the output shaft assembly.

      Note

      Do not drop the input shaft bearing and No. 2 synchronizer ring.

  47. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. B007W2O

      Using a snap ring expander, remove the output shaft bearing shaft snap ring from the output shaft assembly.

  48. REMOVE OUTPUT SHAFT ASSEMBLY


    1. B007QGW

      Using a plastic-faced hammer, remove the output shaft assembly by tapping the intermediate plate.