БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ РАЗБОРКА


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A003FOS

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

  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A003CGY

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

  3. REMOVE SPEEDOMETER SENSOR


    1. A003D5B

      Remove the bolt and speedometer sensor.

    2. Using a screwdriver, remove the O-ring from the speedometer sensor.

  4. REMOVE BACK UP LIGHT SWITCH ASSEMBLY


    1. A003IF2E01

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

      SST
      09817-16011

  5. REMOVE CLUTCH HOUSING


    1. A003EYP

      Remove the 9 bolts.

    2. A003DN8

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

  6. REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A003EPWE01

      Remove the 6 bolts, shift lever shaft housing and clamp from the manual transmission case.

    2. Remove the shift lever shaft housing gasket from the manual transmission case.

  7. REMOVE EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. A003I71

      Using a brass bar and a hammer, remove the extension housing dust deflector from the extension housing.

  8. REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A003DY5

      Remove 8 bolts.

    2. A003AIQ

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

  9. REMOVE TRANSMISSION MAGNET


    1. A003CTC

      Remove the transmission magnet from the extension housing.

  10. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE


    1. A003FPM

      Remove the bolt and extension housing oil receiver pipe from the extension housing.

  11. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A003GA9

      Remove the extension housing oil receiver pipe No.1 from the extension housing.

  12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003DUCE01

      Using SST, remove the manual transmission extension housing oil seal from the extension housing.

      SST
      09308-00010

  13. REMOVE BEARING RETAINER FRONT(MTM)


    1. A003DKM

      Remove the 8 bolts.

    2. w/o Gasket:


      1. Remove the bearing retainer from the transmission case.

    3. w/ Gasket:


      1. Remove the bearing retainer front and transmission front bearing retainer gasket from the manual transmission case.

  14. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A003ARN

      Using a screwdriver, remove the transmission front bearing retainer oil seal from the bearing retainer front.

  15. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A003EUN

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

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


    1. A003CDJ

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

  17. REMOVE MANUAL TRANSMISSION CASE


    1. A003B06

      Stand the manual transmission assembly as shown in the illustration.

    2. Using a plastic hammer, carefully tap off the manual transmission case.

    3. Remove the manual transmission case from the intermediate plate as shown in the illustration.

  18. FIX INTERMEDIATE PLATE


    1. A003FD7

      Fix the intermediate plate in a vise.

  19. REMOVE SHIFT DETENT BALL


    1. A003EFH

      Using a "torx" socket wrench T40, remove the 3 shift detent ball spring seats No.1 from the intermediate plate.

    2. A003HQ5

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

  20. REMOVE SHIFT DETENT BALL NO.2


    1. A003D4U

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

    2. A003I1J

      Using a magnetic finger, remove the compression spring and shift detent ball No.2 from the intermediate plate.

  21. REMOVE GEAR SHIFT FORK SHAFT NO.4


    1. A003B2C

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

    2. A003DQT

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

    3. A003FC2

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

      Note

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

    4. A003CKH

      Remove the ball from the intermediate plate.

    5. A003HH2

      Remove the gear shift fork shaft No.4 and reverse shift fork ball.

  22. REMOVE REVERSE SHIFT HEAD


    1. A003HGW

      Remove the reverse shift head from the reverse shift fork shaft.

  23. REMOVE GEAR SHIFT HEAD NO.3


    1. A003GGL

      Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the gear shift head No.3.

    2. Remove the gear shift head from the reverse shift fork shaft.

  24. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A003DKX

      Using a magnetic finger, remove shift inter lock pin No.2 from the reverse shift fork shaft.

  25. REMOVE REVERSE SHIFT FORK SHAFT


    1. A003GGU

      Remove the reverse shift fork shaft, ball and compression spring.

      Note

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

  26. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A003I39

      Using a magnetic finger, remove the shift inter lock pin No.1 from the intermediate plate.

  27. REMOVE SHIFT INTER LOCK PIN NO.2


    1. A003BIW

      Using a magnetic finger, remove shift inter lock pin No.2 from the gear shift fork shaft No.2.

  28. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A003EAY

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

    2. A003GI4

      Remove the shift fork shaft snap ring from the gear shift fork shaft No.2.

    3. A003FRM

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

  29. REMOVE SHIFT INTER LOCK PIN NO.1


    1. A003F84

      Using a magnetic finger, remove shift inter lock pin No.1 from the intermediate plate.

  30. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A003I29

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

    2. A003IDZ

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

    3. A003CNW

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

    4. Remove the gear shift head No.1 from the gear shift fork shaft No.1.

  31. REMOVE GEAR SHIFT FORK NO.2


    1. A003EL8

      Remove the gear shift fork No.2 from the transmission hub sleeve No.2.

  32. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A003G3Q

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

      Standard clearance
      0.125 to 0.325 mm (0.0049 to 0.0128 in.)
      Maximum clearance
      0.325 mm (0.0128 in.)

  33. REMOVE COUNTER SHAFT 5TH GEAR


    1. A003DEG

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

    2. A003FM3E01

      Using SST, remove the gear spline piece No.5 and synchronizer ring No.3 from the counter gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )
    3. A003E7G

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

  34. REMOVE 5TH GEAR THRUST WASHER


    1. A003C3A

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

    2. A003BNZ

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

  35. REMOVE REVERSE SHIFT ARM BRACKET


    1. A003EXJ

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

  36. REMOVE REVERSE SHIFT ARM


    1. A003F19

      Using a screwdriver, remove the E-ring.

    2. Remove the shift fork from the shift arm.

  37. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003ANO

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

    2. A003C15

      Remove the the reverse idler gear shaft and reverse idler gear sub-assembly from the intermediate plate.

  38. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A003FYE

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

      Standard clearance
      0.04 to 0.08 mm (0.0016 to 0.0031 in.)
      Maximum clearance
      0.13 mm (0.0051 in.)

      If the clearance exceeds the maximum, replace the reverse idler gear.

  39. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003E0BE01

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

      Standard clearance
      0.05 to 0.35 mm (0.0020 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

      If the clearance exceeds the maximum, replace the reverse idler gear and reverse shift arm.

  40. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A003I1B

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

  41. REMOVE COUNTER GEAR


    1. A003CCE

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

    2. A003GMUE01

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

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

  42. REMOVE INPUT SHAFT ASSEMBLY


    1. A003G01

      Remove the input shaft assembly with the 13 input shaft bearings and synchronizer ring No.1 from the output shaft.

  43. REMOVE OUTPUT SHAFT ASSEMBLY


    1. A003DUA

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

    2. A003DMP

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