MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01KH0X

      Remove the filler plug and gasket from the transmission case.

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. A01KFHJ

      Remove the drain plug and gasket from the transmission case.

  3. REMOVE CLUTCH HOUSING


    1. A01KF3J

      Remove the 9 bolts.

    2. A01KFC4

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

  4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01KEQ0E01

      Using SST, remove the back-up light switch from the transmission case.

  5. REMOVE SPEEDOMETER DRIVEN GEAR


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

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

  6. REMOVE EXTENSION HOUSING COVER


    1. A01KFRB

      Remove the 6 bolts, extension housing cover and gasket.

  7. REMOVE EXTENSION HOUSING DUST DEFLECTOR


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

  8. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01KF5Z

      Remove the 6 bolts.

    2. A01KEVV

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

  9. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A01KI0C

      Remove the 10 bolts.

    2. Using a plastic hammer, remove the extension housing.

  10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE


    1. Remove the bolt and oil receiver pipe from the extension housing.

  11. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER


    1. A01KFXD

      Remove the extension housing oil receiver.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01KEJE

      Using a screwdriver and hammer, remove the extension housing oil seal from the extension housing.

  13. REMOVE FRONT BEARING RETAINER


    1. A01KF5I

      Remove the 8 bolts.

    2. A01KEUF

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

  14. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01KF9DE01

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

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

      SST
      09308-00010

  15. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01KI4O

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

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


    1. A01KHAO

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

  17. REMOVE MANUAL TRANSMISSION CASE


    1. A01KF2V

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

  18. REMOVE TRANSMISSION MAGNET


    1. A01KHL0

      Remove the transmission magnet from the intermediate plate.

  19. FIX INTERMEDIATE PLATE


    1. A01KHNM

      Fix the intermediate plate in a vise between aluminum plates.

  20. REMOVE SHIFT DETENT BALL SPRING SEAT


    1. A01KINH

      Using a "TORX" socket wrench T40, remove the shift detent ball spring seat from the intermediate plate.

    2. A01KFL7

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

    3. A01KI1TE03

      Using a "TORX" socket wrench T40, remove the 2 shift detent ball spring seats from the intermediate plate.

    4. A01KI5G

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

  21. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KFAO

      Using a pin punch (5 mm) 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. A01KI17

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

      Note

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

    2. A01KHPT

      Remove the shift fork set 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 magnetic finger, remove the No. 1 shift interlock roller and the shift interlock pin (ball) from the intermediate plate.

  23. REMOVE NO. 1 GEAR SHIFT HEAD


    1. A01KHSD

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

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

  24. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01KI5C

      Using a pin punch (5 mm) 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.

  25. 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 shop rag or piece of cloth to prevent the snap ring from flying off.

    2. A01KGAT

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

    3. A01KEGN

      Using a pin punch (5 mm) and hammer, remove the slotted spring 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 magnetic finger, remove the No. 1 shift interlock roller from the intermediate plate.

  26. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01KIN5

      Using a pin punch (5 mm) and hammer, remove the slotted spring 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 shop rag or 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 magnetic finger, remove the No. 1 shift interlock roller from the intermediate plate.

    5. A01KEUB

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

  27. REMOVE NO. 1 GEAR SHIFT HEAD


    1. A01KHSD

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

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

  28. REMOVE 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 shop rag or piece of cloth to prevent the snap ring from flying off.

    2. A01KG84

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

      Note

      Cover the hole with a shop rag to prevent the reverse shift fork ball from popping out.

    3. A01KGSU

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

  29. REMOVE REVERSE SHIFT FORK


    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 the reverse shift fork from the reverse shift arm.

  30. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01KGQ5

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

  31. REMOVE SPEEDOMETER DRIVE GEAR


    1. A01KEFC

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive gear and ball.

    3. Using a magnetic finger, remove the steel ball.

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

  32. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01KHFN

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

  33. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01KHJ6E02

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

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

  34. 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 (0.0039 to 0.0138 in.)

  35. 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 (0.0059 to 0.0027 in.)

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

  36. 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.

  37. REMOVE NO. 5 GEAR SPLINE PIECE


    1. A01KETXE03

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

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

  38. REMOVE NO. 3 SYNCHRONIZER RING


    1. A01KH8B

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

  39. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01KH7C

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

  40. REMOVE COUNTER 5TH GEAR BEARING


    1. A01KGR1

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

  41. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01KENQ

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

  42. REMOVE 5TH GEAR THRUST WASHER


    1. A01KF7F

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

  43. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01KELK

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

  44. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A01KGXN

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

  45. 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 from the intermediate plate.

  46. REMOVE COUNTER SHAFT CENTER BEARING


    1. A01KIII

      Using a snap ring expander, remove the snap ring.

    2. A01KECTE03

      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 gear.

  47. REMOVE COUNTER GEAR


    1. A01KFJT

      Remove the counter gear assembly from the intermediate plate.

  48. REMOVE INPUT SHAFT ASSEMBLY


    1. A01KFP1

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

      Note

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

  49. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01KFFV

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

  50. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01KIFA

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