MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01BC7V

      Remove the filler plug and gasket from the transmission case.

  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A01BAGZ

      Remove the drain plug and gasket from the transmission case.

  3. REMOVE CLUTCH HOUSING


    1. A01BCT1

      Remove the 9 bolts.

    2. A01BF4K

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

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. A01BDDRE01

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

  5. REMOVE SPEEDOMETER SENSOR


    1. Remove the bolt and speedometer sensor from the extension housing.

    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 deflector from the extension housing.

  8. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01BCK6

      Remove the 6 bolts.

    2. A01BFY0

      Using a plastic 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 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 EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01BE3M

      Remove the extension housing oil receiver pipe No.1.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BH36

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

  13. REMOVE BEARING RETAINER FRONT(MTM)


    1. A01BDNY

      Remove the 8 bolts.

    2. A01BDX3

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

  14. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01BC58E01

      Fix the front bearing retainer in a vise in aluminum plate.

    2. Using SST, remove the transmission front 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 transmission case.

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


    1. A01BHZZ

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

  17. REMOVE MANUAL TRANSMISSION CASE


    1. A01BHMY

      Using a brass bar and hammer, remove the 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. A01BD1A

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

  20. REMOVE SHIFT DETENT BALL SPRING SEAT NO.1


    1. A01BDUZ

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

    2. A01BDBD

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

    3. A01BGEZE03

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

    4. A01BD6X

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

  21. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01BAWA

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

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

  22. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A01BHZV

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

      Note

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

    2. A01BFFO

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

    3. A01BGM8

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

    4. A01BDTI

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

  23. REMOVE SHIFT FORK SHAFT STOPPER


    1. A01BFCI

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

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

  24. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A01BGYW

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

      Note

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

    2. A01BAO9

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

    3. A01BCB1

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

    4. A01BG39

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

    5. A01BAFQ

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

    6. A01BEPS

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

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01BFLI

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

    2. A01BBIC

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

      Note

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

    3. A01BCNY

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

    4. A01BEPS

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

    5. A01BBW3

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

  26. REMOVE GEAR SHIFT FORK SHAFT NO.4


    1. A01BALV

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

      Note

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

    2. A01BB42

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

      Note

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

    3. A01BHVP

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

  27. REMOVE REVERSE SHIFT FORK


    1. A01BBG1

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

    2. A01BBEY

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

  28. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01BGKR

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

  29. REMOVE SPEEDOMETER DRIVE (MTM) GEAR


    1. A01BAFN

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive gear and ball.

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

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

  30. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01BE2A

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

  31. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01BFUYE02

      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 )

  32. 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.)

  33. 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.

  34. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. A01BHTP

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

  35. REMOVE TRANSMISSION HUB SLEEVE NO.3


    1. A01BDC2E01

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

  36. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01BI3RE01

      Using SST, remove the counter 5th gear together with the 2 No. 3 synchromesh shifting keys, 2 No. 3 synchromesh shifting key springs, 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 )

  37. REMOVE GEAR SPLINE PIECE NO.5


    1. A01BGIL

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

  38. REMOVE SYNCHRONIZER RING OUTER NO.3


    1. Remove the synchronizer ring from the counter 5th gear.

  39. REMOVE COUNTER 5TH GEAR BEARING


    1. A01BBWK

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

  40. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3


    1. A01BI6M

      Using a snap ring expander, remove the snap ring.

    2. A01BBJL

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

  41. REMOVE 5TH GEAR THRUST WASHER


    1. A01BFGI

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

  42. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01BE8L

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

  43. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A01BD23

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

  44. 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 from the intermediate plate.

  45. REMOVE COUNTER SHAFT CENTER BEARING


    1. A01BA6R

      Using a snap ring expander, remove the snap ring.

    2. A01BAX7E01

      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.

  46. REMOVE COUNTER GEAR


    1. A01BA8O

      Remove the counter gear assembly from the intermediate plate.

  47. REMOVE INPUT SHAFT ASSEMBLY


    1. A01BB8O

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

      Note

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

  48. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01BHWQ

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

  49. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01BDU2

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