MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01KIHF

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

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. A01KGK4

      Remove the drain plug sub-assembly and gasket from the manual transmission case.

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01KI18

      Remove the clutch release fork sub-assembly and clutch release bearing assembly from the clutch housing.

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. A01KHCR

      Remove the release bearing hub clip and clutch release bearing assembly from the clutch release fork sub-assembly.

  5. REMOVE RELEASE FORK SUPPORT


    1. A01KIR6

      Remove the 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 manual transmission case.

  8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01KGEAE02

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

      SST
      09817-16011

  9. REMOVE SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY


    1. Remove the bolt and speedometer driven gear sub-assembly from the extension housing sub-assembly.

    2. Remove the O-ring from the speedometer driven gear sub-assembly.

  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.

  11. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A01KH3V

      Remove the 10 bolts.

    2. A01KFIM

      Using a brass bar and a hammer, remove the extension housing sub-assembly.

  12. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01KG4L

      Remove the No. 1 extension housing oil receiver pipe from the extension housing sub-assembly.

  13. REMOVE NO. 2 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01KETR

      Remove the bolt and No. 2 extension housing oil receiver pipe from the extension housing sub-assembly.

  14. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01KEYHE01

      Using SST, remove the manual transmission extension housing oil seal from the extension housing sub-assembly.

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

  15. REMOVE FRONT BEARING RETAINER


    1. A01KF5I

      Remove the 8 bolts.

    2. A01KEUF

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

  16. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL


    1. A01KHLUE03

      Fix the front bearing retainer in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Using SST, remove the front transmission 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 front input shaft bearing.

      Note

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

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


    1. A01KHAO

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

      Note

      Use a piece of cloth to prevent the front No. 1 counter gear bearing snap ring from flying off.

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A01KFB1

      Using a brass bar and a hammer, remove the manual 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 manual transmission power take-off cover from the manual 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 in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

  23. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A01KINHE04

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

    2. A01KFL7

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

    3. A01KI1TE09

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

    4. A01KI5G

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

  24. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KFAO

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

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

  25. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01KI17

      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. A01KHPT

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

    3. A01KHJE

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

    4. A01KII0

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

  26. REMOVE NO. 1 GEAR SHIFT HEAD (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KHSD

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

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

  27. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KI5C

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

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

  28. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01KI4X

      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. A01KGAT

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

    3. A01KEGN

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

    4. A01KFZX

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

    5. A01KIB6

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

    6. A01KFWQ

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

  29. REMOVE NO. 3 GEAR SHIFT FORK SHAFT (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KIN5

      Using a 5 mm pin punch and a hammer, remove the shift fork slotted pin from the No. 3 gear shift fork shaft.

    2. A01KFKW

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Note

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

    3. A01KHIO

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

    4. A01KFWQ

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

    5. A01KEUB

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

  30. REMOVE NO. 1 GEAR SHIFT HEAD (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KHSD

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

    2. Remove the No. 1 gear shift head from the No. 3 gear shift fork shaft.

  31. REMOVE NO. 4 GEAR SHIFT FORK SHAFT (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KI62

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

      Note

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

    2. A01KG84

      Remove the No. 4 gear shift fork shaft from the intermediate plate.

      Note

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

    3. A01KGSU

      Using a magnet hand, remove the reverse shift fork ball and compression spring from the reverse shift fork.

  32. REMOVE REVERSE SHIFT FORK (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KH06

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

    2. A01KFEN

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

      Note

      Use a piece of cloth to prevent the reverse shift arm end shaft ring from flying off.

  33. REMOVE REVERSE SHIFT ARM BRACKET (w/ No. 4 Gear Shift Fork Shaft)


    1. A01KGQ5

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

  34. REMOVE NO. 3 GEAR SHIFT FORK SHAFT (w/o No. 4 Gear Shift Fork Shaft)


    1. A01KIN5

      Using a 5 mm pin punch and a hammer, remove the shift fork slotted pin from the No. 3 gear shift fork.

    2. A01KEBC

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Note

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

    3. A01KEOI

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

    4. A01KHWK

      Remove the No. 3 gear shift fork and No. 3 gear shift fork shaft from the intermediate plate.

  35. REMOVE REVERSE SHIFT FORK (w/o No. 4 Gear Shift Fork Shaft)


    1. A01KFE4

      Remove the reverse shift fork from the reverse shift arm.

  36. REMOVE REVERSE SHIFT ARM BRACKET (w/o No. 4 Gear Shift Fork Shaft)


    1. A01KFUU

      Remove the torsion spring from the reverse shift arm bracket.

    2. A01KIOP

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

    3. A01KGWX

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

      Note

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

    4. A01KIN3

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

  37. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01KGHGE02
      Text in Illustration
      *a Turn
      *b Hold

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

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

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

  38. REMOVE SPEEDOMETER DRIVE GEAR


    1. A01KHMB

      Remove the speedometer drive gear from the output shaft assembly.

  39. REMOVE SPEEDOMETER DRIVE GEAR KEY OR BALL


    1. A01KH6R

      Remove the speedometer drive gear key or ball from the output shaft assembly.

  40. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01KEBX

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

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      If the clearance is not as specified, replace the counter shaft 5th gear with a new one.

  41. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01KFUJ

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

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      If the clearance is not as specified, replace the counter shaft 5th gear with a new one.

  42. REMOVE REAR COUNTER GEAR SHAFT SNAP RING


    1. A01KFDI

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

      Note

      Use a piece of cloth to prevent the rear counter gear shaft snap ring from flying off.

  43. REMOVE NO. 5 GEAR SPLINE PIECE (for Single Type Synchronizer Ring)


    1. A01KETXE08
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09952-06010, 09953-05020, 09954-05021, 09957-04010 )

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

  44. REMOVE NO. 3 SYNCHRONIZER RING (for Single Type Synchronizer Ring)


    1. A01KH8B

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

  45. REMOVE COUNTER SHAFT 5TH GEAR (for Single Type Synchronizer Ring)


    1. A01KFP4

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

  46. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY (for Single Type Synchronizer Ring)


    1. A01KENQE01
      Text in Illustration
      *1 Counter Shaft 5th Gear
      *2 No. 3 Transmission Hub Sleeve
      *3 No. 3 Synchromesh Shifting Key
      *4 No. 3 Synchromesh Shifting Key Spring

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

  47. REMOVE NO. 3 TRANSMISSION HUB SLEEVE (for Lever Type Synchronizer Ring)


    1. A01KI2D

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

  48. REMOVE COUNTER SHAFT 5TH GEAR (for Lever Type Synchronizer Ring)


    1. A01KGHDE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the counter shaft 5th gear together with the outer No. 3 synchronizer ring and No. 5 gear spline piece from the counter gear assembly.

      SST
      09950-40011   ( 09951-00040, 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-03021, 09957-04010, 09958-04011 )

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

  49. REMOVE NO. 5 GEAR SPLINE PIECE (for Lever Type Synchronizer Ring)


    1. A01KH3EE05
      Text in Illustration
      *1 No. 5 Gear Spline Piece
      *2 Outer No. 3 Synchronizer Ring
      *3 Counter Shaft 5th Gear

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

  50. REMOVE OUTER NO. 3 SYNCHRONIZER RING (for Lever Type Synchronizer Ring)


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

  51. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY (for 1-piece Type)


    1. A01KIHB

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

      Note

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

    2. A01KHS3E02
      Text in Illustration
      *1 Counter Shaft 5th Gear
      *2 No. 3 Synchromesh Shifting Key
      *3 No. 3 Synchromesh Shifting Key Spring

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

  52. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY (for 2-piece Type)


    1. A01KEMM

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

      Note

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

    2. A01KHIYE01
      Text in Illustration
      *1 Counter Shaft 5th Gear
      *2 No. 3 Synchromesh Shifting Key
      *3 No. 3 Synchromesh Shifting Key Spring

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

  53. REMOVE COUNTER 5TH GEAR BEARING


    1. A01KGR1

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

  54. REMOVE 5TH GEAR THRUST WASHER


    1. A01KF7F

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

  55. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01KELK

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

  56. REMOVE REAR OUTPUT SHAFT BEARING RETAINER


    1. A01KGXN

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

  57. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KGMOE03

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

  58. REMOVE CENTER COUNTER SHAFT BEARING


    1. A01KIII

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

      Note

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

    2. A01KFV7E02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the center counter shaft bearing from the counter gear assembly.

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

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

      Tech Tips

      Remove the center counter shaft bearing while tapping the tip of the counter gear assembly with a plastic hammer so that the counter gear assembly does not hit the side wall of the output shaft gear by being pushed forward.

  59. REMOVE COUNTER GEAR ASSEMBLY


    1. A01KFJT

      Remove the counter gear assembly from the intermediate plate.

      Note

      Do not drop the counter gear assembly.

  60. REMOVE INPUT SHAFT ASSEMBLY


    1. A01KFP1

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

      Note

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

  61. 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 assembly.

      Note

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

  62. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01KGZL

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