MANUAL TRANSMISSION UNIT (for 1GR-FE) DISASSEMBLY


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    A01DMUA

    1. Remove the clutch release fork with the clutch release bearing from the transmission unit.

    2. Remove the release fork support from the transmission unit.

    3. A01DU31

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

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

    A01DN00

    1. Remove the 4 bolts.

    2. Using a plastic-faced hammer, remove the floor shift control shift lever retainer.

  3. REMOVE SHIFT LEVER HOUSING

    A01DSZF

    1. Remove the bolt and shift lever housing.

  4. REMOVE MANUAL TRANSMISSION CASE COVER

    A01DT1J

    1. Remove the 4 bolts and transmission case cover.

  5. REMOVE SHIFT DETENT BALL PLUG

    A01DSC2

    1. Using a 10 mm hexagon socket wrench, remove the shift detent ball plug from the transfer adapter.

    2. Remove the ball and compression spring from the transfer adapter.

  6. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. Using a belt and wooden block, securely fasten the transmission to the workbench.

    2. A01DPCM

      Using a chisel and hammer, unstake the rear set nut.

    3. A01DR4PE03
      Text in Illustration
      *1 Input Shaft

      Engage 5th gear, and then secure the input shaft using SST.

      SST
      09322-35010   ( 09322-03010, 09322-03020, 09322-03030, 90105-12087, 90170-12030, 94622-51200 )

      Tech Tips


      • Install SST securely so that the part labeled A is in-line with the input shaft.

      • Make sure that the part labeled A moves back and forth by hand after installing SST.

    4. A01DNZSE01

      Using an L-type handle and SST, remove the rear set nut from the output shaft.

      SST
      09326-35010   ( 09326-03010 )

    5. Remove the belt and wooden block from the transmission.

    6. A01DQ2ZE01
      Text in Illustration
      *1 Output Shaft Bearing
      *2 Output Shaft Spacer

      Remove the output shaft bearing and spacer.

  7. REMOVE TRANSFER ADAPTER

    A01DOZ6E01

    1. Remove the 10 bolts and 4 brackets.

      Text in Illustration
      *1 Bracket
    2. A01DUNT

      Using a plastic-faced hammer, carefully tap off the transfer adapter to remove it.

      Tech Tips

      Place a brass bar against the rib portion of the case.

  8. REMOVE MANUAL TRANSMISSION FILLER PLUG

    A01DO8W

    1. Remove the 2 transmission filler plugs and 2 gaskets from the transfer adapter.

  9. REMOVE NO. 1 OIL RECEIVER PIPE

    A01DUJV

    1. Remove the No. 1 oil receiver pipe from the transfer adapter.

  10. REMOVE OIL SEPARATOR PACKING SEAL

    A01DQAU

    1. Remove the oil separator packing seal from the transfer adapter.

  11. REMOVE TRANSFER ADAPTER CASE PLUG


    1. A01DR5X

      Using a 14 mm hexagon socket wrench, remove the case plug from the transfer adapter.

  12. REMOVE REAR OUTPUT SHAFT BEARING

    A01DUCSE01

    1. Using SST, remove the 2 rear output shaft bearings (outer race) from the transfer adapter.

      SST
      09308-00010

  13. REMOVE COUNTER GEAR REAR RADIAL BALL BEARING

    A01DOTD

    1. Remove the bolt and bearing lock plate.

    2. A01DLVYE01

      Using SST, remove the counter gear rear radial ball bearing from the transfer adapter.

      SST
      09308-00010

  14. REMOVE TRANSFER ADAPTER NEEDLE ROLLER BEARING


    1. Remove the roller bearing from the transfer adapter.

  15. REMOVE TRANSMISSION OIL SEPARATOR

    A01DMZP

    1. Remove the 2 bolts and oil separator.

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    A01DUEX

    1. Remove the reverse idler gear shaft bolt and gasket from the reverse idler gear shaft.

  17. REMOVE TRANSMISSION MIDDLE CASE


    1. A01DMWOE01
      Text in Illustration
      *1 Bolt
      *2 Collar

      Remove the bolt and collar.

    2. A01DU7X

      Remove the 11 bolts.

    3. A01DLTM

      Using a plastic-faced hammer, carefully tap off the transmission middle case to remove it.

      Tech Tips

      Place a brass bar against the rib portion of the case.

  18. REMOVE DRAIN PLUG SUB-ASSEMBLY

    A01DMAD

    1. Remove the drain plug and gasket from the transmission middle case.

  19. REMOVE NO. 2 OIL RECEIVER PIPE

    A01DT3P

    1. Remove the No. 2 oil receiver pipe from the transmission middle case.

  20. REMOVE SHIFT AND SELECT LEVER SHAFT

    A01DTCH

    1. Remove the shift and select lever shaft from the reverse gear shaft.

  21. REMOVE SHIFT AND SELECT LEVER


    1. A01DQAP

      Using a screwdriver, remove the E-ring.

    2. A01DQ5A

      Using a 5 mm pin punch and hammer, tap out the straight pin.

    3. A01DMZ3

      Remove the bolt, interlock plate, select cam and select lever from the lever shaft.

    4. Remove the lock ball pin and spring from the shift and select lever.

  22. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    A01DUNYE01

    1. Using SST, remove the back-up light switch and gasket.

      SST
      09817-16011

  23. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE


    1. A01DOBH

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.154 mm (0.00394 to 0.00606 in.)
      Maximum clearance
      0.154 mm (0.00606 in.)

      • If the clearance is more than the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case.

  24. REMOVE REVERSE IDLER GEAR

    A01DS8Z

    1. Remove the reverse idler gear shaft, reverse idler gear bearing and reverse idler gear.

  25. REMOVE FRONT TRANSMISSION CASE

    A01DRMH

    1. Remove the 4 bolts and interlock bracket.

    2. A01DRGI

      Using a 27 mm hexagon wrench, remove the case plug.

    3. A01DT2F

      Tie the input shaft, counter gear and control assembly with a piece of rope or string.

    4. A01DS6Q

      Expand the 2 snap rings and lift up the output shaft, input shaft, counter gear shaft and control assembly.

    5. A01DQJE

      Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the clutch housing with a plastic-faced hammer.

      Note

      Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This could cause the ball and spring to come out.

    6. Separate the output shaft, input shaft, counter gear shaft and control assembly.

  26. REMOVE NO. 3 OIL RECEIVER PIPE

    A01DMKQ

    1. Remove the No. 3 oil receiver pipe from the front transmission case.

  27. REMOVE FRONT BEARING SHAFT SNAP RING

    A01DOX8

    1. Using snap ring pliers, remove the 2 snap rings.

  28. REMOVE TRANSMISSION CASE OIL SEAL

    A01DUOHE01

    1. Using SST, remove the transmission case oil seal from the front transmission case.

      SST
      09308-00010

  29. REMOVE TRANSMISSION CASE NEEDLE BEARING


    1. Using SST, remove the bearing from the front transmission case.

      A01DS19E01
      Text in Illustration
      *1 Transmission Case Needle Bearing - -
      *a Hold *b Turn

  30. REMOVE NO. 3 GEAR SHIFT FORK

    A01DPCX

    1. Remove the bolt and No. 3 gear shift fork.

  31. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    A01DQC3

    1. Remove the No. 3 shift fork shaft, shift detent ball and compression spring.

  32. REMOVE NO. 2 GEAR SHIFT FORK

    A01DNIZ

    1. Remove the bolt and No. 2 gear shift fork.

  33. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    A01DPDT

    1. Remove the No. 2 shift fork shaft, shift detent ball and compression spring.

  34. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01DTEP

      Using a 5 mm pin punch and hammer, tap out the slotted pin.

    2. A01DLWO

      Remove the No. 1 shift fork shaft, shift detent ball, compression spring and No. 1 shift head.

  35. REMOVE NO. 1 GEAR SHIFT FORK

    A01DORV

    1. Using a 5 mm pin punch and hammer, tap out the slotted pin.

    2. A01DUFT

      Remove the No. 2 shift head and No. 1 shift fork.

  36. REMOVE NO. 4 GEAR SHIFT FORK

    A01DPDO

    1. Using a 5 mm pin punch and hammer, tap out the slotted pin.

    2. Remove the No. 4 shift fork.

  37. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

    A01DRH0

    1. Remove the No. 4 shift fork shaft, shift detent ball and compression spring.

  38. REMOVE NO. 1 RELEASE ARM

    A01DQYX

    1. Using a screwdriver, remove the E-ring.

    2. A01DSZVE02

      Remove the shift arm pivot and release arm.