MANUAL TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01XC9M

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

  2. REMOVE DRAIN PLUG


    1. A01XL7X

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

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  5. REMOVE RELEASE FORK SUPPORT


    1. A01XEKF

      Remove the release fork support from the clutch housing.

  6. REMOVE CLUTCH RELEASE FORK BOOT


    1. A01XDH0

      Remove the clutch release fork boot from the clutch housing.

  7. REMOVE CLUTCH HOUSING


    1. A01XICH

      Remove the 9 bolts.

    2. A01XI72

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

  8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01XK73E12

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

      SST
      09817-16011

  9. REMOVE RESTRICT PIN


    1. A01XDZQ

      Remove the 2 restrict pins from the transfer adapter.

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


    1. A01XCF9

      Remove the 4 bolts and floor shift control shift lever retainer sub-assembly.

    2. Remove the gasket.

  11. REMOVE TRANSFER ADAPTER


    1. A01XJU3

      Remove the 10 bolts.

    2. A01XLY8

      Using a brass bar and hammer, tap off the transfer adapter from the manual transmission case.

  12. REMOVE TRANSFER OIL RECEIVER PIPE


    1. A01XI31

      Remove the transfer oil receiver pipe from the transfer adapter.

  13. REMOVE SHIFT AND SELECT LEVER


    1. A01XD8G

      Remove the bolt from the shift lever housing.

    2. A01XM4VE01
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Remove the shift and select lever and shift lever housing from the transfer adapter.

  14. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01XILH

      Using a T40 "TORX" socket wrench, remove the reverse restrict pin plug.

    2. A01XDSG

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

    3. A01XH4U

      Remove the reverse restrict pin assembly.

  15. REMOVE TRANSFER ADAPTER OIL SEAL


    1. A01XFC4

      Using a screwdriver and hammer, tap out the transfer adapter oil seal from the transfer adapter.

  16. REMOVE FRONT BEARING RETAINER


    1. A01XMLH

      Remove the 8 bolts.

    2. A01XGV9

      Using a brass bar and hammer, tap off the front bearing retainer from the manual transmission case.

  17. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01XE8AE01

      Secure the front bearing retainer in a vise between aluminum plates.

    2. Using SST, tap out the transmission front bearing retainer oil seal.

      SST
      09308-00010

  18. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01XCTK

      Using a snap ring expander, remove the front bearing shaft snap ring from the input shaft front bearing.

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


    1. A01XLAF

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01XMEL

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

  21. REMOVE TRANSMISSION MAGNET


    1. A01XCKQ

      Remove the transmission magnet from the intermediate plate.

  22. FIX INTERMEDIATE PLATE


    1. A01XDN4

      Secure the intermediate plate in a vise between aluminum plates.

  23. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A01XDG4

      for Type A:

      Using a 6 mm hexagon socket wrench, remove the No. 1 shift detent ball spring seat from the intermediate plate.

    2. A01XCH7

      for Type B:

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

    3. A01XJ1S

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

    4. A01XJTE

      for Type A:

      Using a 6 mm hexagon socket wrench, remove the 2 No. 1 shift detent ball spring seats from the intermediate plate.

    5. A01XF5G

      for Type B:

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

    6. A01XI4F

      Using a magnet hand, remove the 2 compression springs and 2 detent balls from the intermediate plate.

  24. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01XEDB

      Using 2 screwdrivers and a hammer, tap off 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. A01XK6N

      Remove the bolt from the No. 2 shift fork.

    3. A01XCMH

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

    4. A01XCDY

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

    5. A01XIOR

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

  25. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01XKNQ

      Using 2 screwdrivers and a hammer, tap off 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. A01XCOQ

      Remove the bolt from the No. 1 shift fork.

    3. A01XEAI

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

    4. A01XEIX

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

  26. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01XKD4

      Using a 5 mm pin punch and hammer, tap out the shift fork set slotted spring pin from the No. 3 shift fork.

    2. A01XD35

      Using 2 screwdrivers and a hammer, tap off the snap ring from the No. 3 gear shift fork shaft.

      Note

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

    3. A01XFT8

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

    4. A01XMPV

      Remove the No. 3 shift fork and No. 3 gear shift fork shaft from the intermediate plate.

    5. A01XDLF

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

  27. REMOVE REVERSE SHIFT FORK


    1. A01XMA7

      Remove the reverse shift fork from the reverse shift arm.

  28. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01XEDE

      Remove the torsion spring from the reverse shift arm bracket.

    2. A01XLA0

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

    3. A01XCKY

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

    4. A01XCK3

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

  29. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING (for Rear Bearing Side)


    1. A01XFXO

      Using 2 screwdrivers and a hammer, tap off the output shaft bearing shaft snap ring from the output shaft rear bearing.

      Note

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

  30. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01XLZKE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the output shaft rear bearing and output shaft spacer from the output shaft.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00300 )

  31. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE


    1. A01XKAE

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      • If the clearance is not as specified, replace the counter 5th gear.

  32. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE


    1. A01XJPF

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      • If the clearance is not as specified, replace the counter 5th gear bearing with a new one.

  33. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. A01XHSC

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

      Note

      Use a piece of cloth to prevent the counter gear rear shaft snap ring from flying off.

  34. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01XDD5

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

  35. REMOVE NO. 5 GEAR SPLINE PIECE


    1. A01XFNZE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the counter 5th gear together with the counter 5th gear bearing, 2 No. 3 synchromesh shifting keys, No. 3 synchromesh shifting key spring, No. 3 synchronizer ring and No. 5 gear spline piece from the counter 5th gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010 )

  36. REMOVE NO. 5 GEAR SPLINE PIECE


    1. A01XF4S

      Remove the No. 5 gear spline piece from the counter 5th gear.

  37. REMOVE OUTER NO. 3 SYNCHRONIZER RING


    1. Remove the outer No. 3 synchronizer ring from the counter 5th gear.

  38. REMOVE COUNTER 5TH GEAR BEARING


    1. A01XCSZ

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

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. A01XL9C

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

    2. A01XEHIE01
      Text in Illustration
      *1 No. 3 Synchromesh Shifting Key Spring
      *2 No. 3 Synchromesh Shifting Key
      *3 Counter 5th Gear

      Remove the No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring from the counter 5th gear.

  40. REMOVE 5TH GEAR THRUST WASHER


    1. A01XGND

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

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01XETW

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

  42. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A01XEOH

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

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01XJ9R

      Pull out the reverse idler gear shaft from the rear side and remove the reverse idler gear sub-assembly from the intermediate plate.

  44. REMOVE COUNTER SHAFT CENTER BEARING


    1. A01XMOT

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

    2. A01XEI0E01

      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 )
      09950-60010   ( 09951-00260 )

      Note

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

  45. REMOVE COUNTER GEAR


    1. A01XLSN

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT


    1. A01XMR9

      Remove the input shaft and No. 2 synchronizer ring from the output shaft.

      Note

      Do not drop the input shaft bearing or No. 2 synchronizer ring.

  47. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING (for Center Bearing Side)


    1. A01XCQU

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

  48. REMOVE OUTPUT SHAFT


    1. A01XCCG

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