MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A003ED8

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A003DW4

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

  3. REMOVE CLUTCH HOUSING


    1. A003HRG

      Remove the 9 bolts.

    2. A003BP5

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

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. A003CE0E01

      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. A003FHJ

      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. A003BCE

      Remove the 6 bolts.

    2. A003H8X

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

  9. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A003DO9

      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. A003FTU

      Remove the No. 1 extension housing oil receiver pipe.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003HE7

      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. A003GT0

      Remove the 8 bolts.

    2. A003D38

      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. A003H99E01

      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. A003CG3

      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. A003H72

      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. A003BVF

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

  18. REMOVE TRANSMISSION MAGNET


    1. A003GJU

      Remove the transmission magnet from the intermediate plate.

  19. FIX INTERMEDIATE PLATE


    1. A003GTR

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

  20. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A003AXS

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

    2. A003C0R

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

    3. A003FVD

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

    4. A003BB3

      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. A003HCK

      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. A003BDA

      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. A003BIB

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

    3. A003DMQ

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

    4. A003I4V

      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. A003F10

      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. A003DG3

      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. A003HHD

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

    3. A003I7L

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

    4. A003FUU

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

    5. A003B4O

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

    6. A003DLC

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

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. A003F5H

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

    2. A003F36

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

    3. A003EEP

      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. A003DL1

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

  26. REMOVE REVERSE SHIFT FORK


    1. A003AM2

      Remove the reverse shift fork from the reverse shift arm.

  27. REMOVE REVERSE SHIFT ARM BRACKET


    1. A003AT2

      Remove the torsion spring from the reverse shift arm bracket.

    2. A003GJ2

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

    3. A003DR7

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

    4. A003DC0

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

  28. REMOVE SPEEDOMETER DRIVE (MTM) GEAR


    1. A003EAP

      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. A003GWN

      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. A003FM1E04
      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. A003CEY

      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. A003ESM

      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. A003FPI

      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. A003I7U

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

  35. REMOVE COUNTER SHAFT 5TH GEAR


    1. A003CEHE06
      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. A003BTF

      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. A003GMT

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

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING


    1. A003DNK

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

    2. A003HLZ

      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. A003E95

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

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A003DUM

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

  42. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A003DOQ

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

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003HTJE03

      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. A003GUB

      Using a snap ring expander, remove the snap ring.

    2. A003FL8E01

      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. A003CFO

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT ASSEMBLY


    1. A003AV3

      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. A003DEI

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

  48. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A003DK8

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