MANUAL TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY (for 1GR-FE)

    B00115E

    1. Loosen the hose clamp, and remove the breather hose.

  2. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY (for 1VD-FTV)

    B001195

    1. Remove the wire harness clamp.

    2. Loosen the hose clamp, and remove the breather hose.

  3. REMOVE CLUTCH HOUSING

    B0010YLE06
    *1 for 1VD-FTV:
    *2 for 1GR-FE:

    1. Remove the 10 bolts and clutch housing.

  4. REMOVE FILLER PLUG

    B001176

    1. Remove the filler plug.

    2. Remove the gasket from the filler plug.

  5. REMOVE DRAIN PLUG

    B00115N

    1. Remove the drain plug.

    2. Remove the gasket from the drain plug.

  6. REMOVE MANUAL TRANSMISSION CASE PLUG

    B001169

    1. Using a T55 "TORX" socket wrench, remove the transmission case plug.

    2. Remove the gasket from the transmission case plug.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    B00112RE02

    1. Disconnect the wire harness clamp.

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

      SST
      09817-16011

  8. REMOVE SHIFT POSITION SWITCH (for 1VD-FTV)

    B0010TTE02

    1. Disconnect the wire harness clamp.

    2. Using SST, remove the shift position switch and gasket.

      SST
      09817-16011

  9. REMOVE CONTROL SHAFT COVER

    B001110

    1. Remove the 6 bolts and control shaft cover.

  10. REMOVE REVERSE RESTRICT PIN ASSEMBLY

    B00113E

    1. Remove the 2 restrict pins.

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

    B0010ZG

    1. Remove the 4 bolts.

    2. B0010YU

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

  12. REMOVE NO. 1 REVERSE RESTRICT PIN

    B0010VZ

    1. Remove the slotted pin.

    2. B00110I

      Remove the No. 1 reverse restrict pin and spring.

  13. REMOVE TRANSMISSION OIL PUMP COVER

    B001YJF

    1. Remove the 5 bolts and oil pump cover.

    2. B001X8K

      Using a magnet hand, remove the 2 pins.

    3. Remove the oil pump cover O-ring from the oil pump cover.

  14. REMOVE TRANSMISSION OIL PUMP COVER OIL SEAL

    B00113GE02
    *1 Protective Tape

    1. Using a screwdriver, pry out the oil pump cover oil seal.

      Note

      Be careful not to damage the oil seal and oil pump cover contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  15. REMOVE FRONT BEARING RETAINER (MTM)

    B00115H

    1. Remove the 8 bolts and front bearing retainer.

  16. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    B0010TXE02
    *1 Protective Tape

    1. Using a screwdriver, pry out the oil seal.

      Note

      Be careful not to damage the oil seal and front bearing retainer contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  17. REMOVE SHIFT AND SELECT LEVER SHAFT

    B00112P

    1. Using a 14 mm hexagon wrench, remove the interlock hole plug.

    2. B001113E03
      *1 Front Side
      *2 Shift And Select Lever
      *3 Shift And Select Lever Shaft
      *4 Shift Lever Housing

      Remove the 3 bolts, shift and select lever shaft, shift and select lever and shift lever housing.

  18. REMOVE TRANSFER ADAPTER SUB-ASSEMBLY

    B00116C

    1. Remove the 11 bolts and transfer adapter.

  19. REMOVE TRANSFER ADAPTER STRAIGHT PIN AND RING PIN

    B00114QE01
    *1 Upper Side:
    *2 Rear Side:

    1. Remove the 4 straight pins from the transfer adapter.

    2. Remove the 2 ring pins from the transfer adapter.

  20. REMOVE TRANSFER ADAPTER PLUG

    B0011AM

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

  21. REMOVE MANUAL TRANSMISSION OIL STRAINER SUB-ASSEMBLY

    B0010XL

    1. Remove the 2 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  22. REMOVE TRANSMISSION MAGNET

    B00114A

    1. Remove the transmission magnet.

  23. REMOVE NO. 2 REVERSE IDLER THRUST WASHER

    B0010T3

    1. Remove the thrust washer.

  24. REMOVE REVERSE IDLER GEAR


    1. Remove the reverse idler gear.

  25. REMOVE REVERSE IDLER GEAR BUSH OR BEARING


    1. Remove the bearing.

  26. REMOVE REVERSE IDLER THRUST WASHER


    1. Remove the thrust washer.

  27. REMOVE REVERSE IDLER GEAR SHAFT


    1. Remove the reverse idler gear shaft.

  28. REMOVE REVERSE IDLER GEAR SHAFT WOODRUFF KEY


    1. Remove the woodruff key from the reverse idler gear shaft.

  29. REMOVE MANUAL TRANSMISSION CASE SUB-ASSEMBLY

    B0010UZ

    1. Using a snap ring expander, remove the 2 snap rings from the input shaft and counter gear.

    2. B0010X9

      Using a brass bar and hammer, carefully tap the transmission case.

    3. Remove the transmission case from the intermediate plate.

  30. REMOVE NO. 1 OIL RECEIVER PIPE (MTM)

    B00119F

    1. Remove the 2 bolts and oil receiver pipe from the transmission case.

  31. REMOVE TRANSFER ADAPTER STRAIGHT PIN

    B0010UYE01
    *1 Upper Side:
    *2 Front Side:

    1. Remove the 4 straight pins from the transmission case.

  32. REMOVE INTERMEDIATE PLATE STRAIGHT PIN

    B0010TEE01
    *1 Front Side:
    *2 Rear Side:

    1. Remove the 4 straight pins from the intermediate plate.

  33. REMOVE MANUAL TRANSMISSION CASE RECEIVER


    1. B00111W

      Remove the 3 bolts and oil receiver from the intermediate plate.

  34. REMOVE SHIFT DETENT BALL PLUG

    B001179

    1. Using a T40 "TORX" socket wrench, remove the 4 ball plugs.

    2. Using a magnet hand, remove the 4 springs and 4 balls.

  35. REMOVE SHIFT FORK SHAFT SNAP RING

    B001100

    1. Using 2 screwdrivers and a hammer, tap out the 4 snap rings.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

  36. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

    B0010TO

    1. Remove the No. 4 gear shift fork set bolt.

    2. B0010ZQ

      Remove the No. 4 gear shift fork shaft and 2 balls.

  37. REMOVE REVERSE SHIFT FORK


    1. Remove the reverse shift fork.

  38. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    B00110M

    1. Using a magnet hand, remove the ball.

    2. B0010XA

      Remove the No. 3 gear shift fork set bolt.

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

    4. B00118Z

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

  39. REMOVE NO. 3 GEAR SHIFT FORK


    1. Remove the No. 3 gear shift fork.

  40. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

    B0010T0

    1. Using a magnet hand, remove the interlock pin.

    2. B00118G

      Remove the No. 1 gear shift fork set bolt.

    3. Remove the No. 1 gear shift fork shaft.

    4. B00116P

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

  41. REMOVE NO. 1 GEAR SHIFT FORK


    1. Remove the No. 1 gear shift fork.

  42. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    B0010Y0

    1. Using a magnet hand, remove the interlock pin.

    2. B001166

      Remove the No. 2 gear shift fork set bolt.

    3. Remove the No. 2 gear shift fork shaft.

  43. REMOVE NO. 2 GEAR SHIFT FORK


    1. Remove the No. 2 gear shift fork.

  44. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING


    1. B001115C02
      *a Protective Tape

      Using 2 screwdrivers and a hammer, tap out the snap ring.

      Note


      • Do not damage the output shaft.

      • Use a piece of cloth to prevent the snap ring from flying off.

      Tech Tips

      Tape the screwdriver tip before use.

  45. REMOVE NO. 1 TRANSMISSION HUB SLEEVE


    1. B00110D

      Remove the No. 1 transmission hub sleeve from the No. 4 transmission clutch hub.

  46. REMOVE REVERSE GEAR


    1. B00117RC01
      *a Turn
      *b Hold

      Using SST, remove the reverse gear, reverse synchronizer ring set and No. 4 transmission clutch hub from the output shaft.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04010, 09954-04020, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00300 )

  47. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. B0010VJ

      Remove the transmission clutch hub from the reverse gear.

    2. B0010USC02
      *a Protective Tape

      Using a screwdriver, remove the 3 shifting keys and 3 springs from the No. 4 transmission clutch hub.

      Note


      • Do not drop the shifting key.

      • Do not damage the No. 4 transmission clutch hub and spring.

      Tech Tips

      Push down the spring as shown in the illustration and remove the shifting key.

  48. REMOVE REVERSE SYNCHRONIZER RING SET


    1. Remove the reverse synchronizer ring set from the reverse gear.

  49. REMOVE REVERSE GEAR BEARING


    1. Remove the reverse gear bearing.

  50. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER

    B0010WR

    1. Remove the 4 bolts and rear bearing retainer.

  51. REMOVE COUNTER GEAR

    B00114G

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

    2. B00112ZE01

      Using SST, remove the outer race.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04011, 09957-04010, 09958-04011 )

      Note

      Do not drop the counter gear. Hold the front side of the counter gear when removing the bearing outer race.

    3. B00117I

      Using a screwdriver, remove the center bearing and counter gear.

  52. REMOVE INPUT SHAFT ASSEMBLY

    B001188

    1. Remove the input shaft from the output shaft.

      Note

      Do not drop the input shaft bearing.

  53. REMOVE NO. 2 SYNCHRONIZER RING


    1. Remove the No. 2 synchronizer ring from the input shaft.

  54. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    B001161

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

  55. REMOVE OUTPUT SHAFT ASSEMBLY

    B0010UI

    1. 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.