MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01BEGO

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

  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A01BF91

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

  3. REMOVE SPEEDOMETER SENSOR


    1. A01BBNG

      Remove the bolt and speedometer sensor.

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

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. A01BFJ8E01

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

      SST
      09817-16011

  5. REMOVE CLUTCH HOUSING


    1. A01BDHB

      Remove the 9 bolts.

    2. A01BGHS

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

  6. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01BCB4E01

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

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

  7. REMOVE EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. A01BD5X

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

  8. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01BBCN

      Remove 8 bolts.

    2. A01BA9O

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

  9. REMOVE TRANSMISSION MAGNET


    1. A01BDH2

      Remove the transmission magnet from the extension housing.

  10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01BC1W

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

  11. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01BCZ1

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

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BBAFE01

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

      SST
      09308-00010

  13. REMOVE BEARING RETAINER FRONT(MTM)


    1. A01BGM7

      Remove the 8 bolts.

    2. w/o Gasket:


      1. Remove the bearing retainer from the transmission case.

    3. w/ Gasket:


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

  14. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01BFDV

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

  15. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01BA6P

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

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


    1. A01BFQ4

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

  17. REMOVE MANUAL TRANSMISSION CASE


    1. A01BH5N

      Stand the manual transmission assembly as shown in the illustration.

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

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

  18. FIX INTERMEDIATE PLATE


    1. A01BAMW

      Fix the intermediate plate in a vise.

  19. REMOVE SHIFT DETENT BALL


    1. A01BG02

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

    2. A01BE37

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

  20. REMOVE SHIFT DETENT BALL NO.2


    1. A01BA76

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

    2. A01BB37

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

  21. REMOVE GEAR SHIFT FORK SHAFT NO.4


    1. A01BD4X

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

    2. A01BBR0

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

    3. A01BCQ8

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

      Note

      Use a shop rag to prevent the snap ring from flying off.

    4. A01BAH5

      Remove the ball from the intermediate plate.

    5. A01BAP0

      Remove the gear shift fork shaft No.4 and reverse shift fork ball.

  22. REMOVE REVERSE SHIFT HEAD


    1. A01BBBW

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

  23. REMOVE GEAR SHIFT HEAD NO.3


    1. A01BDXT

      Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the gear shift head No.3.

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

  24. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A01BDMN

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

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01BAS0

      Remove the reverse shift fork shaft, ball and compression spring.

      Note

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

  26. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A01BFTN

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

  27. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A01BH4F

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

  28. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A01BE6X

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

    2. A01BC33

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

    3. A01BG5H

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

  29. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A01BCEQ

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

  30. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A01BA49

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

    2. A01BEVL

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

    3. A01BBAW

      Using a pin punch (5 mm) and a hammer, remove the 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.

  31. REMOVE GEAR SHIFT FORK NO.2


    1. A01BBZD

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

  32. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01BCNN

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

      Standard clearance
      0.125 to 0.325 mm (0.0049 to 0.0128 in.)
      Maximum clearance
      0.325 mm (0.0128 in.)

  33. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01BEL3

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

    2. A01BDYIE01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )
    3. A01BH4M

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

  34. REMOVE 5TH GEAR THRUST WASHER


    1. A01BG71

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

    2. A01BB8D

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

  35. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01BH00

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

  36. REMOVE REVERSE SHIFT ARM


    1. A01BGNW

      Using a screwdriver, remove the E-ring.

    2. Remove the shift fork from the shift arm.

  37. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01BG8F

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

    2. A01BB1R

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

  38. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A01BFK0

      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.)

      If the clearance exceeds the maximum, replace the reverse idler gear.

  39. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01BFD0E01

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

      Standard clearance
      0.05 to 0.35 mm (0.0020 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

      If the clearance exceeds the maximum, replace the reverse idler gear and reverse shift arm.

  40. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A01BAYK

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

  41. REMOVE COUNTER GEAR


    1. A01BC1O

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

    2. A01BBA5E01

      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 )

  42. REMOVE INPUT SHAFT ASSEMBLY


    1. A01BDSJ

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

  43. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01BFG1

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

    2. A01BC72

      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.