MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01DNHGE01

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

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. A01DO2OE01

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

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    A01DPK5

    1. Remove the release fork and release bearing from the clutch housing.

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    A01DPFIE01

    1. Remove the clip and release bearing from the release fork.

  5. REMOVE RELEASE FORK SUPPORT


    1. A01DUP9E01

      Remove the release fork support from the front transmission case.

  6. REMOVE CLUTCH RELEASE FORK BOOT


    1. A01DS6FE01

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01DQHTE01

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

      SST
      09817-16011

  8. REMOVE FRONT TRANSMISSION CASE


    1. A01DTWAE01

      Remove the 9 bolts.

    2. A01DS6WE01

      Using a plastic-faced hammer, tap off the front transmission case from the manual transmission case.

  9. REMOVE RESTRICT PIN


    1. A01DQFS

      Remove the 2 restrict pins from the transfer adapter.

  10. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY


    1. A01DQWE

      Remove the 4 bolts from the transfer adapter.

    2. Remove the gasket from the adapter.

  11. REMOVE SHIFT DETENT BALL


    1. A01DTEBE05

      Using a T40 "TORX" socket, remove the spring seat from the transfer adapter.

    2. A01DQ5WE03

      Using a magnet hand, remove the compression spring and shift detent ball from the transfer adapter.

  12. REMOVE TRANSFER ADAPTER


    1. A01DMNO

      Remove the bolt from the shift lever housing.

    2. A01DTNF

      Remove the 8 bolts.

    3. A01DSI5E01

      Using a plastic-faced hammer, tap off the transfer adapter from the manual transmission case.

  13. REMOVE TRANSMISSION MAGNET


    1. A01DPXEE01

      Remove the magnet from the transfer adapter.

  14. REMOVE TRANSFER OIL RECEIVER PIPE


    1. A01DQY1E01

      Remove the receiver pipe from the transfer adapter.

  15. REMOVE SHIFT AND SELECT LEVER


    1. A01DMPWE03
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Remove the shift and select lever and shift lever housing from the transfer adapter.

  16. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01DSBWE01

      Using a T40 "TORX" socket, remove the plug from the transfer adapter.

    2. A01DPXBE01

      Using a 5 mm pin punch and hammer, tap out the restrict slotted spring pin from the transfer adapter.

    3. A01DTJFE01

      Remove the restrict pin from the transfer adapter.

  17. REMOVE TRANSFER ADAPTER OIL SEAL


    1. A01DU1AE01

      Using a screwdriver and hammer, tap out the oil seal from the transfer adapter.

      Note

      Be careful no to damage the surface which contacts the oil seal.

  18. REMOVE FRONT BEARING RETAINER


    1. A01DNM0E01

      Remove the 8 bolts.

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

  19. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01DQCEE01

      Using a screwdriver, pry out the oil seal from the front bearing retainer.

      Note

      Be careful no to damage the surface which contacts the oil seal.

  20. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01DQ9WE01

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

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


    1. A01DOO4E01

      Using a snap ring expander, remove the snap ring from the counter gear front bearing.

  22. REMOVE MANUAL TRANSMISSION CASE


    1. A01DQH2E01

      Stand the transmission as shown in the illustration.

    2. Using a plastic-faced hammer, carefully tap off the transmission case as shown in the illustration.

    3. Remove the transmission case from the intermediate plate.

  23. FIX INTERMEDIATE PLATE


    1. A01DRA2E01

      Fix the intermediate plate in a vise between aluminum plates.

  24. REMOVE SHIFT DETENT BALL


    1. A01DMYHE01

      Using a T40 "TORX" socket, remove the spring seat and 2 ball plugs from the intermediate plate.

    2. A01DOIQE01

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

  25. REMOVE NO. 2 SHIFT DETENT BALL


    1. A01DPH6E01

      Using a T40 "TORX" socket, remove the spring seat from the intermediate plate.

    2. A01DMYBE01

      Using a magnet hand, remove the compression spring and No. 2 detent ball from the intermediate plate.

  26. REMOVE NO. 4 GEAR SHIFT FORK SHAFT


    1. A01DPAXE01

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

    2. A01DU7P

      Remove the shift detent ball from the reverse shift head.

    3. A01DQWJ

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

  27. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A01DU8VE01

      Using a 5 mm pin punch and a hammer, tap out the slotted spring pin from the reverse shift head

    2. A01DQTEE01

      Remove the reverse shift head and No. 5 gear shift fork shaft from the intermediate plate.

  28. REMOVE NO. 2 SHIFT INTERLOCK PIN


    1. A01DSSHE01

      Using a magnet hand, remove the No. 2 shift interlock pin from the No. 3 gear shift fork shaft.

  29. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01DOZY

      Using 2 screwdrivers and a hammer, remove the reverse shift head ring from the No. 3 shift fork shaft.

    2. A01DR4N

      Using a 5 mm pin punch and a hammer, tap out the slotted spring pin from the No. 3 shift fork shaft.

    3. A01DRSO

      Remove the No. 3 shift fork shaft from the intermediate plate.

  30. REMOVE REVERSE SHIFT ARM


    1. A01DN9Z

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

    2. A01DPQH

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

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

    4. A01DSUP

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

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

  31. REMOVE NO. 3 SHIFT INTERLOCK PIN


    1. Using a magnet hand, remove the No. 3 shift interlock pin from the intermediate.

  32. REMOVE NO. 2 SHIFT INTERLOCK PIN


    1. A01DSDME01

      Using a magnet hand, remove the No. 2 shift interlock pin from the No. 1 gear shift fork shaft.

  33. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01DSHYE01

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

    2. A01DT3NE01

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

    3. A01DQWOE01

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

  34. REMOVE NO. 1 SHIFT INTERLOCK PIN


    1. A01DTNHE01

      Using a magnet hand, remove the shift interlock pin from the intermediate plate.

  35. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01DOI1E01

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

    2. A01DQ5BE01

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

    3. A01DUKU

      Remove the No. 2 gear shift fork shaft, No. 1 gear shift fork and No. 2 gear shift fork from the intermediate plate.

  36. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01DQBVE01

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

      Standard clearance
      0.10 to 0.30 mm (0.00394 to 0.0118 in.)

      • If the result is not as specified, replace the counter shaft 5th gear.

  37. REMOVE COUNTER SHAFT 5TH GEAR


    1. A01DPJV

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

    2. A01DR4WE01

      Using SST, remove the No. 5 gear spline and the No. 1 synchronizer ring from the counter gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )
    3. A01DRTAE01

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

  38. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01DTLRE01
      Text in Illustration
      *1 No. 3 Transmission Hub Sleeve
      *2 No. 3 Synchromesh Shifting Key Spring
      *3 Counter 5th Gear Bearing
      *4 No. 3 Synchromesh Shifting Key
      *5 Counter Shaft 5th Gear

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

  39. REMOVE 5TH GEAR THRUST WASHER


    1. A01DOJJE01

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

  40. REMOVE 5TH GEAR BEARING INNER RACE LOCK BALL


    1. A01DUK6E01

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

  41. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01DUS4

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

  42. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01DSZQ

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

    2. A01DPJ6E05

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

  43. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A01DRJME01

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

      Standard clearance
      0.04 to 0.08 mm (0.00158 to 0.00314 in.)
      Maximum clearance
      0.08 mm (0.00314 in.)

      • If the clearance is more than the maximum, replace the needle roller bearing.

  44. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01DPPD

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

      Standard clearance
      0.05 to 0.28 mm (0.00197 to 0.0110 in.)
      Maximum clearance
      0.28 mm (0.00110 in.)

      • If the clearance is more than the maximum, replace the reverse idler gear and reverse shift arm.

  45. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A01DRWYE01

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

  46. REMOVE COUNTER GEAR ASSEMBLY


    1. A01DN8TE01

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

    2. A01DM4DE01

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

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

  47. REMOVE INPUT SHAFT ASSEMBLY


    1. A01DUVP

      Remove the input shaft with the 13 input shaft bearings and No. 2 synchronizer ring from the output shaft.

  48. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A01DRR6E01

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

    2. A01DM6Z

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