MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01BC7V

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A01BAGZ

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

  3. REMOVE CLUTCH HOUSING


    1. A01BCT1

      Remove the 9 bolts.

    2. A01BF4K

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

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. A01BDDRE01

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

      SST
      09817-16011

  5. REMOVE SPEEDOMETER SENSOR


    1. Remove the bolt and speedometer sensor from the extension (MTM) housing sub-assembly.

    2. Remove the O-ring from the speedometer sensor.

  6. REMOVE EXTENSION HOUSING(MTM) COVER


    1. A01BD48

      Remove the 6 bolts, extension housing (MTM) cover and gasket.

  7. REMOVE EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. Using a brass bar and a hammer, remove the extension housing dust (MTM) deflector from the extension (MTM) housing sub-assembly.

  8. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01BCK6

      Remove the 6 bolts.

    2. A01BFY0

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

  9. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01BFQ0

      Remove the 10 bolts.

    2. Using a plastic-faced hammer, remove the extension (MTM) housing sub-assembly.

  10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE


    1. Remove the bolt and extension housing oil receiver pipe from the extension (MTM) housing sub-assembly.

  11. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01BE3M

      Remove the No. 1 extension housing oil receiver pipe.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BH36

      Using a screwdriver and hammer, remove the manual transmission extension housing oil seal from the extension (MTM) housing sub-assembly.

  13. REMOVE FRONT BEARING RETAINER (MTM)


    1. A01BDNY

      Remove the 8 bolts.

    2. A01BDX3

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

  14. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL


    1. A01BC58E01

      Fix the front bearing retainer (MTM) in a vise in aluminum plate.

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

      SST
      09308-00010

  15. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01BH1E

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

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


    1. A01BHZZ

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

  17. REMOVE MANUAL TRANSMISSION CASE


    1. A01BHMY

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

  18. REMOVE TRANSMISSION MAGNET


    1. A01BBVQ

      Remove the transmission magnet from the intermediate plate.

  19. FIX INTERMEDIATE PLATE


    1. A01BAI9

      Fix the intermediate plate in a vise in between aluminum plates.

  20. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A01BDUZ

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

    2. A01BDBD

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

    3. A01BF47

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

    4. A01BB3D

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

  21. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01BAWA

      Using a 5 mm pin punch 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. A01BHP2

      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. A01BDXU

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

    3. A01BC9H

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

    4. A01BDTI

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

  23. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01BFCI

      Using a 5 mm pin punch 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.

  24. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01BI2K

      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. A01BAO9

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

    3. A01BAJB

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

    4. A01BGHZ

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

    5. A01BB8Z

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

    6. A01BEPS

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

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01BFLI

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

    2. A01BDB3

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

    3. A01BANA

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

      Note

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

    4. A01BI38

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

  26. REMOVE REVERSE SHIFT FORK


    1. A01BAAZ

      Remove the reverse shift fork from the reverse shift arm.

  27. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01BBM9

      Remove the torsion spring from the reverse shift arm bracket.

    2. A01BI6X

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

    3. A01BD03

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

    4. A01BD37

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

  28. REMOVE SPEEDOMETER DRIVE (MTM) GEAR


    1. A01BAFN

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive (MTM) gear and steel ball.

    3. Using a magnet hand, remove the steel ball.

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

  29. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01BCZI

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

  30. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01BGXGE04
      Text in Illustration
      *a Turn
      *b Hold

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

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

  31. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01BGP4

      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.)

  32. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01BFJ5

      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.

  33. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. A01BI4P

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

  34. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01BALD

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

  35. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01BEI5E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the counter shaft 5th gear together with the counter 5th gear bearing, 2 No. 3 synchromesh shifting keys, No. 3 synchromesh shifting key spring, outer No. 3 synchronizer ring and No. 5 gear spline piece from the counter gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )

  36. REMOVE NO. 5 GEAR SPLINE PIECE


    1. A01BGIL

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

  37. REMOVE OUTER NO. 3 SYNCHRONIZER RING


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

  38. REMOVE COUNTER 5TH GEAR BEARING


    1. A01BBWK

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

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING


    1. A01BI6M

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

    2. A01BBJL

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

  40. REMOVE 5TH GEAR THRUST WASHER


    1. A01BAF3

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

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01BFMY

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

  42. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A01BD23

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

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01BHT2E03

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

  44. REMOVE COUNTER SHAFT CENTER BEARING


    1. A01BGEC

      Using a snap ring expander, remove the snap ring.

    2. A01BA5TE01

      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 assembly gear.

  45. REMOVE COUNTER GEAR


    1. A01BA8O

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT ASSEMBLY


    1. A01BB8O

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

      Note

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

  47. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01BCIB

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

  48. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01BH2F

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