MANUAL TRANSMISSION UNIT(for 1GR-FE) DISASSEMBLY

PROCEDURE


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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

    A01XFL0

    1. Remove the 4 bolts.

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

  3. REMOVE SHIFT LEVER HOUSING

    A01XG2G

    1. Remove the bolt and shift lever housing.

  4. REMOVE MANUAL TRANSMISSION CASE COVER

    A01XKAO

    1. Remove the 4 bolts and manual transmission case cover.

  5. REMOVE SHIFT DETENT BALL PLUG

    A01XDSB

    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 manual transmission to the workbench.

    2. A01XJXF

      Using a chisel and hammer, unstake the manual transmission output shaft rear set nut.

    3. B001GKJE05
      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 )

      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. B001CA0E02

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

      SST
      09326-35010   ( 09326-03010 )

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

    6. B001DGVE01
      Text in Illustration
      *1 Rear Output Shaft Bearing
      *2 Output Shaft Spacer

      Remove the rear output shaft bearing (inner race) and output shaft spacer.

  7. REMOVE TRANSFER ADAPTER

    B001HLQE02

    1. Remove the 10 bolts and 4 brackets.

      Text in Illustration
      *1 Bracket
    2. A01XI5V

      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 transfer adapter.

  8. REMOVE MANUAL TRANSMISSION FILLER PLUG

    A01XLUB

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

  9. REMOVE NO. 1 OIL RECEIVER PIPE

    A01XD9X

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

  10. REMOVE OIL SEPARATOR PACKING SEAL

    A01XLL2

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

  11. REMOVE TRANSFER ADAPTER CASE PLUG


    1. A01XI2A

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

  12. REMOVE REAR OUTPUT SHAFT BEARING

    B001GU1E01

    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

    A01XE25

    1. Remove the bolt and bearing lock plate.

    2. B001H9DE01

      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 transfer adapter needle roller bearing from the transfer adapter.

  15. REMOVE TRANSMISSION OIL SEPARATOR

    A01XIVL

    1. Remove the 2 bolts and transmission oil separator.

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    A01XFFH

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

  17. REMOVE TRANSMISSION MIDDLE CASE


    1. B001CNGE02
      Text in Illustration
      *1 Bolt
      *2 Collar

      Remove the bolt and collar.

    2. A01XI63

      Remove the 11 bolts.

    3. A01XFEU

      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 transmission middle case.

  18. REMOVE DRAIN PLUG SUB-ASSEMBLY

    A01XFW5

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

  19. REMOVE NO. 2 OIL RECEIVER PIPE

    A01XMAL

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

  20. REMOVE SHIFT AND SELECT LEVER SHAFT

    A01XH2L

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

  21. REMOVE SHIFT AND SELECT LEVER


    1. A01XKJX

      Using a screwdriver, remove the E-ring.

    2. A01XLF8

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

    3. A01XGIH

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

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

  22. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    B001I1VE04

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

      SST
      09817-16011

  23. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE


    1. A01XG76

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.13 to 0.154 mm (0.00512 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 front transmission case.

  24. REMOVE REVERSE IDLER GEAR

    A01XISX

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

  25. REMOVE FRONT TRANSMISSION CASE


    1. A01XFNO

      Remove the 4 bolts from the shift interlock bracket.

    2. A01XM7I

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

    3. A01XINU

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

    4. A01XH9H

      Expand the 2 front bearing shaft snap rings and lift up the output shaft assembly, input shaft assembly, counter gear assembly, shift interlock bracket, gear shift forks and gear shift fork shafts.

    5. A01XCDS

      Remove the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks and gear shift fork shafts while gently tapping the clutch housing with a plastic-faced hammer.

      Note

      Take care not to subject the output shaft assembly, input shaft assembly, counter gear assembly, shift interlock bracket, gear shift forks and gear shift fork shafts to any impact. This could cause the ball and spring to come out.

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

  26. REMOVE NO. 3 OIL RECEIVER PIPE

    A01XK7D

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

  27. REMOVE FRONT BEARING SHAFT SNAP RING

    A01XIWE

    1. Using snap ring pliers, remove the 2 front bearing shaft snap rings.

  28. REMOVE TRANSMISSION CASE OIL SEAL

    B001FFUE01

    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 transmission case needle bearing from the front transmission case.

      SST
      09319-60020
      B001IIEC01
      Text in Illustration
      *1 Transmission Case Needle Bearing - -
      *a Hold - -
      B001DLW Turn - -

  30. REMOVE NO. 3 GEAR SHIFT FORK

    A01XKRX

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

  31. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    A01XLV2

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

  32. REMOVE NO. 2 GEAR SHIFT FORK

    A01XCZ3

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

  33. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    A01XGGN

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

  34. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01XFZD

      Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the No. 1 gear shift head.

    2. A01XMRD

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

  35. REMOVE NO. 1 GEAR SHIFT FORK


    1. A01XJQZ

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

    2. A01XHKU

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

  36. REMOVE NO. 4 GEAR SHIFT FORK

    A01XI0O

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

    2. Remove the No. 4 gear shift fork.

  37. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

    A01XJ8E

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

  38. REMOVE NO. 1 RELEASE ARM

    A01XKNP

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

    2. A01XHLM

      Remove the shift arm pivot and No. 1 release arm.