MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01KIHF

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

  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A01KGK4

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

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01KI18

      Remove the clutch release fork and the clutch release bearing from the clutch housing.

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. A01KHCR

      Remove the clutch bearing hub clip and remove the clutch release bearing from the clutch release fork.

  5. REMOVE RELEASE FORK SUPPORT


    1. A01KIR6

      Remove the clutch release fork support from the clutch housing.

  6. REMOVE CLUTCH RELEASE FORK BOOT


    1. A01KH43

      Remove the clutch release fork boot from the clutch housing.

  7. REMOVE CLUTCH HOUSING


    1. A01KE8X

      Remove the 9 bolts.

    2. A01KFON

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

  8. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSEMBLY


    1. Remove the bolt and the speedometer driven gear from the transmission extension housing.

  9. REMOVE BACK-UP LAMP SWITCH ASSEMBLY


    1. A01KGEAE02

      Using SST, remove the back-up lamp switch assembly and gasket from the transmission case.

      SST
      09817-16011

  10. REMOVE SHIFT LEVER SHAFT HOUSING ASSEMBLY


    1. A01KF5Z

      Remove the 6 bolts.

    2. A01KEVV

      Using a plastic hammer, remove the shift lever shaft housing assembly from the transmission case.

  11. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01KH3V

      Remove the 10 bolts.

    2. A01KFIM

      Using a brass bar and a hammer, remove the transmission extension housing from the transmission case.

  12. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01KG4L

      Remove the extension housing oil receiver pipe No. 1 from the transmission extension housing.

  13. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.2


    1. A01KETR

      Remove the bolt and remove the extension housing oil receiver pipe No. 2 from the transmission extension housing.

  14. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01KEYHE01

      Using SST, remove the transmission extension housing oil seal from the transmission extension housing.

      SST
      09950-60010   ( 09951-00640 )
      09950-70010   ( 09951-07100 )

  15. REMOVE BEARING RETAINER FRONT (MTM)


    1. A01KF5I

      Remove the 8 bolts.

    2. A01KEUF

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

  16. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01KF9DE01

      Fix the transmission front bearing retainer.

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

      SST
      09308-00010

  17. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01KI4O

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

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


    1. A01KHAO

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A01KFB1

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

  20. REMOVE MANUAL TRANSMISSION POWER TAKE-OFF COVER


    1. A01KFK1

      Remove the 4 bolts.

    2. A01KH9O

      Using a brass bar and a hammer, remove the transmission power take-off cover from the transmission case.

  21. REMOVE TRANSMISSION MAGNET


    1. A01KHL0

      Remove the transmission magnet from the intermediate plate.

  22. FIX INTERMEDIATE PLATE


    1. A01KHNM

      Fix the intermediate plate on the vice though aluminum plate.

  23. REMOVE SHIFT DETENT BALL SPRING SEAT NO.1


    1. A01KHXB

      Using a hexagon wrench, remove the shift detent ball spring seat No. 1 from the intermediate plate.

    2. A01KFL7

      Using a magnetic finger, remove the shift detent ball low side spring and the shift detent ball from the intermediate plate.

    3. A01KEBK

      Using a hexagon wrench, remove the 3 shift detent ball spring seats No. 1 from the intermediate plate.

    4. A01KE9E

      Using a magnetic finger, remove the 2 shift detent ball low side springs and the 2 shift detent balls from the intermediate plate.

  24. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KFAO

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

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

  25. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A01KI17

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

      Note

      Cover the snap ring with a piece of cloth to stop it from flying out.

    2. A01KHPT

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

    3. A01KHJE

      Pull out the gear shaft No. 1 to the front side, and remove the gear shift fork shaft No. 1 from the intermediate plate.

    4. A01KII0

      Using a magnetic finger, remove the shift interlock roller and the shift interlock pin (ball) No. 1 from the intermediate plate.

  26. REMOVE GEAR SHIFT HEAD NO.1


    1. A01KHSD

      Using a pin punch (5 mm) and a hammer, remove the shift head slotted pin from the shift fork shaft No. 1.

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

  27. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KI5C

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

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

  28. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A01KI4X

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

      Note

      Cover the snap ring with a piece of cloth to stop it from flying out.

    2. A01KGAT

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

    3. A01KEGN

      Using a pin punch (5 mm) and a hammer, remove the shift head slotted pin from the shift fork shaft No. 2.

    4. A01KFZX

      Pull out the gear shift fork shaft No. 2 to the front side, and remove the gear shift fork shaft No. 2 and the gear shift head No. 2 from the intermediate plate.

    5. A01KIB6

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

    6. A01KFWQ

      Using a magnetic finger, remove the shift interlock roller from the intermediate plate.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01KIN5

      Using a pin punch (5 mm) and a hammer, remove the shift lever shaft set slotted pin from the reverse shift fork shaft.

    2. A01KFKW

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

      Note

      Cover the snap ring with a piece of cloth to stop it from flying out.

    3. A01KHIO

      Pull out the reverse shift fork shaft to the front side, and remove the gear shift fork No. 3 and the reverse shift fork shaft from the intermediate plate.

    4. A01KFWQ

      Using a magnetic finger, remove the shift interlock roller No. 1 from the intermediate plate.

    5. A01KEUB

      Using a magnetic finger, remove the reverse shift fork ball from the reverse shift fork.

  30. REMOVE GEAR SHIFT HEAD NO.1


    1. A01KHSD

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

    2. Remove the gear shift head No. 1 from the reverse shift fork shaft.

  31. REMOVE GEAR SHIFT FORK SHAFT NO.4


    1. A01KI62

      Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 4.

      Note

      Cover the snap ring with a piece of cloth to stop it from flying out.

    2. A01KG84

      Pull out the gear shift fork shaft No. 4 to the front side, and remove the gear shift fork shaft No. 4 from the intermediate plate.

      Note

      Cover the hole with a piece of cloth to stop the reverse shift fork ball from falling out.

    3. A01KHRA

      Using a magnetic finger, remove the reverse shift fork compression spring from the reverse shift fork.

  32. REMOVE REVERSE SHIFT FORK


    1. A01KH06

      Remove the reverse shift fork with reverse shift arm from the intermediate plate.

    2. A01KFEN

      Using a screwdriver, remove the reverse shift arm end shaft ring and remove the reverse shift fork from the reverse shift arm.

  33. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01KGQ5

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

  34. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01KHJ6E02

      Using SST, remove the output shaft rear bearing from the output shaft.

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

  35. REMOVE SPEEDOMETER DRIVE (MTM) GEAR


    1. A01KHMB

      Remove the speedometer drive gear from the output shaft.

  36. REMOVE SPEEDOMETER DRIVE GEAR (MTM) KEY OR BALL


    1. A01KH6R

      Remove the speedometer drive gear ball from the output shaft.

  37. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01KEBX

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

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

  38. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01KFUJ

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

      Standard clearance
      0.015 to 0.068 mm (0.00059 to 0.0027 in.)

      If the value is not within the specification, replace the counter shaft 5th gear bearing with a new one.

  39. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. A01KFDI

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

  40. REMOVE GEAR SPLINE PIECE NO.5


    1. A01KETXE02

      Using SST, remove the gear spline piece No. 5 from the counter gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010 )

  41. REMOVE SYNCHRONIZER RING NO.3


    1. A01KEXS

      Remove the synchronizer ring No. 3 from the counter gear.

  42. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01KFP4

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

  43. REMOVE COUNTER 5TH GEAR BEARING


    1. A01KGR1

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

  44. REMOVE TRANSMISSION HUB SLEEVE NO.3


    1. A01KGY1

      Remove the transmission hub sleeve No. 3, 3 synchromesh shifting key No. 3 and the 2 synchromesh shifting key spring No. 3 from the counter shaft 5th gear.

  45. REMOVE 5TH GEAR THRUST WASHER


    1. A01KF7F

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

  46. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01KELK

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

  47. REMOVE OUTPUT SHAFT REAR BEARING (MTM) RETAINER


    1. A01KGXN

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

  48. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KGMOE03

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

  49. REMOVE COUNTER SHAFT CENTER BEARING


    1. A01KIII

      Using a snap ring expander, remove the snap ring.

    2. A01KECTE02

      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 the tip of the counter gear is tapped with a plastic hammer, so that the counter gear assembly will not hit the side wall of the output shaft gear by being pushed forward at the time of removing the bearing.

  50. REMOVE COUNTER GEAR ASSEMBLY


    1. A01KFJT

      Remove the counter gear assembly from the intermediate plate.

  51. REMOVE INPUT SHAFT ASSEMBLY


    1. A01KFP1

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

      Note

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

  52. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01KHWN

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

  53. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01KGZL

      Using a plastic hammer, remove the output shaft assembly with tapping the intermediate plate.