MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01KHBB

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

  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A01KIEG

      Using a hexagon wrench 10 mm, remove the drain plug and the drain plug gasket from the manual transmission case.

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


    1. A01KGM7

      Remove the bolt and the speedometer driven gear sub-assembly.

    2. A01KHD6

      Using a screwdriver, remove the speedometer shaft sleeve clip and the speedometer driven gear from the speedometer sensor.

    3. A01KEK2

      Using a screwdriver, remove the speedometer sensor O-ring from the speedometer sensor.

  4. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01KHN2

      Remove the clutch release fork sub-assembly and the clutch release bearing assembly from the manual transmission case.

  5. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. A01KF1V

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

  6. REMOVE RELEASE FORK SUPPORT


    1. A01KGLA

      Remove the clutch release fork support from the manual transmission case.

  7. REMOVE CLUTCH RELEASE FORK BOOT


    1. A01KEBT

      Remove the clutch release fork boot from the manual transmission case.

  8. REMOVE BACK-UP LAMP SWITCH ASSEMBLY


    1. A01KHY9E02

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

      SST
      09817-16011

  9. REMOVE CLUTCH HOUSING


    1. A01KFM0

      Remove the 9 bolts.

    2. A01KI2F

      Tap on the circumference of the clutch housing with a plastic hammer to remove the clutch housing from the manual transmission case.

  10. REMOVE SHIFT LEVER SHAFT HOUSING ASSEMBLY


    1. A01KEUV

      Remove the 6 bolts and the shift lever shaft housing assembly from the manual transmission case.

    2. Remove the shift lever shaft housing gasket from the manual transmission case.

  11. REMOVE EXTENSION HOUSING DUST (MTM) DEFLECTOR


    1. A01KHOQ

      Using a brass bar and a hammer, remove the extension housing dust deflector from the extension housing.

  12. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01KFCJ

      Remove the 8 bolts.

    2. A01KHZI

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

  13. REMOVE TRANSMISSION (MTM) MAGNET


    1. A01KHA3

      Remove the transmission magnet from the extension housing.

  14. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.2


    1. A01KHXR

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

  15. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01KI3V

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

  16. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01KEBUE02

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

      SST
      09308-00010

  17. REMOVE BEARING RETAINER FRONT (MTM)


    1. A01KIR9

      Remove the 8 bolts.

    2. Remove the bearing retainer front and the transmission front bearing retainer gasket from the manual transmission case.

  18. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01KFKV

      Using a screwdriver, remove the transmission front bearing retainer oil seal from the bearing retainer front.

  19. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01KIP5

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

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


    1. A01KH9R

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

  21. REMOVE MANUAL TRANSMISSION CASE


    1. A01KEB2

      Stand the manual transmission assembly as shown.

    2. Using a plastic hammer, carefully tap off the manual transmission case.

    3. Remove the manual transmission case from the intermediate plate as shown.

  22. FIX INTERMEDIATE PLATE


    1. A01KEM2

      Fix the intermediate plate in a vise.

  23. REMOVE SHAFT DETENT BALL


    1. A01KET2

      Using "TORX" socket wrench T40, remove the 3 shift detent ball spring seats No. 1 from the intermediate plate.

    2. A01KEVU

      Using a magnetic finger, remove the 3 shift detent ball low side compression springs and the 3 shift detent balls from the intermediate plate.

  24. REMOVE SHIFT DETENT BALL NO.2


    1. A01KEE6

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

    2. A01KI1U

      Using a magnetic finger, remove the shift detent ball compression spring and the shift detent ball No. 2 from the intermediate plate.

  25. REMOVE GEAR SHIFT FORK SHAFT NO.4


    1. A01KEPI

      Remove the shift fork bolt from the gear shift fork No. 3.

    2. A01KIL9

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

    3. A01KHN3

      Remove the reverse shift restrict ball from the reverse shift head.

    4. A01KI3S

      Remove the gear shift fork shaft No. 4, shift inter lock ball No. 1 and the gear shift fork No. 3 from the intermediate plate.

  26. REMOVE REVERSE SHIFT HEAD


    1. A01KEVO

      Remove the reverse shift head ring from the reverse shift fork shaft.

    2. A01KHVI

      Remove the reverse shift head from the reverse shift fork shaft.

  27. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A01KHHJ

      Using a magnetic finger, remove the shift inter lock pin No. 2 from the reverse shift fork shaft.

  28. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01KGUG

      Remove the shift fork shaft snap ring from the reverse shift fork shaft.

    2. A01KEQR

      Using a pin punch and a hammer, drive out the shift lever shaft set slotted spring pin from the reverse shift fork.

    3. A01KGDN

      Remove the reverse shift fork shaft from the intermediate plate.

  29. REMOVE REVERSE SHIFT ARM


    1. A01KILT

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

    2. A01KF0V

      Using a screwdriver, remove the reverse shift arm E-ring.

    3. Remove the reverse shift fork from the reverse shift arm.

    4. A01KHG6

      Using a screwdriver, remove the shift arm shoe shaft snap ring.

    5. Remove the shift arm shoe from the reverse shift arm.

  30. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A01KE9Y

      Using a magnetic finger, remove the shift inter lock pin No. 1 from the intermediate plate.

  31. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A01KFPH

      Using a magnetic finger, remove the shift inter lock pin No. 2 from the gear shift fork shaft No. 2.

  32. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A01KHYA

      Using a pin punch and a hammer, drive out the shift lever shaft set slotted spring pin from the gear shift fork No. 2.

    2. A01KF2K

      Remove the shift fork shaft snap ring from the gear shift fork shift No. 2.

    3. A01KII5

      Remove the gear shift fork shaft No. 2 from the intermediate plate.

  33. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A01KGR9

      Using a magnetic finger, remove the shift inter lock pin No. 1 from the intermediate plate.

  34. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A01KHF2

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

    2. A01KEZL

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

    3. A01KFJA

      Using a pin punch and a hammer, drive out the shift lever shaft set slotted spring pin from the gear shift head No. 1.

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

  35. REMOVE GEAR SHIFT FORK NO.2


    1. A01KGFN

      Remove the gear shift fork No. 2 from the transmission hub sleeve No. 2.

  36. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01KE9W

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

      Standard clearance
      0.10 to 0.30 mm (0.0039 to 0.0118 in.)
      Maximum clearance
      0.30 mm (0.0118 in.)

  37. REMOVE COUNTER SHAFT 5TH GEAR ASSEMBLY


    1. A01KHTS

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

    2. A01KETHE02

      Using SST, remove the gear spline piece No. 5 and the synchronizer ring No. 3 from the counter gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )
    3. A01KH34

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

  38. REMOVE 5TH GEAR THRUST WASHER


    1. A01KFLO

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

    2. A01KF9Q

      Using a magnetic finger, remove the 5th gear bearing inner race lock ball from the counter gear.

  39. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01KH80

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

  40. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KG1J

      Remove the bolt and the reverse idler gear shaft stopper from the intermediate plate.

    2. A01KG28

      Remove the reverse idler gear shaft and the reverse idler gear sub-assembly from the intermediate plate.

  41. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A01KHCT

      Using a dial indicator, inspect the reverse idler gear radial clearance.

      Standard clearance
      0.04 to 0.08 mm (0.0016 to 0.0031 in.)
      Maximum clearance
      0.13 mm (0.0051 in.)

  42. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KIQ8

      Using a feeler gauge, inspect the clearance between the reverse idler gear and the shift arm shoe.

      Standard clearance
      0.05 to 0.28 mm (0.0020 to 0.0110 in.)
      Maximum clearance
      0.5 mm (0.0197 in.)

  43. REMOVE OUTPUT SHAFT REAR BEARING (MTM) RETAINER


    1. A01KIHS

      Using "TORX" socket wrench T40, remove the 4 screws and the output shaft rear bearing retainer from the intermediate plate.

  44. REMOVE COUNTER GEAR ASSEMBLY


    1. A01KIO8

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

    2. A01KI6RE01

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

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

  45. REMOVE INPUT SHAFT ASSEMBLY


    1. A01KI2H

      Remove the input shaft assembly with the 13 input shaft bearings and the synchronizer ring No. 1 from the output shaft.

  46. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01KECZ

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

    2. A01KFOT

      Remove the output shaft assembly from the intermediate plate by pulling on the output shaft assembly and tapping on the intermediate plate with a plastic hammer.