БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ РАЗБОРКА

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01SDG0

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

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. A01SC9X

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

  3. REMOVE CLUTCH RELEASE FORK BOOT

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  5. REMOVE RELEASE FORK SUPPORT

    Click here

  6. REMOVE CLUTCH HOUSING


    1. A01SAERC04
      *A for 1TR-FE, 2TR-FE
      *B except 1TR-FE, 2TR-FE

      Remove the 9 bolts.

    2. A01SCOA

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  8. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01SE4VC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

      Remove the 2 reverse restrict pin assemblies from the extension housing sub-assembly.

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


    1. A01SBRJC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

      Remove the 6 bolts.

    2. Remove the floor shift control shift lever retainer sub-assembly.

    3. Remove the control shift lever retainer gasket.

  10. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A01SEFR

      Remove the 10 bolts.

    2. A01SBVO

      Using a plastic-faced hammer, tap the extension housing off of the intermediate plate. Make sure to remove the shift and select lever from the shift fork shafts before completely removing the extension housing sub-assembly.

  11. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. A01SAYWC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

      Remove the bolt from the shift lever housing.

    2. A01SDW6C01
      *a Protective Tape

      Using a screwdriver, pry out the extension housing dust deflector.

      Note

      Be careful not to damage the extension housing dust deflector.

      Tech Tips

      Put tape on the screwdriver tip before use.

  12. REMOVE NO. 2 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01SAGR

      Remove the No. 2 extension housing oil receiver pipe from the extension housing sub-assembly.

  13. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. Remove the bolt and No. 1 extension housing oil receiver pipe.

  14. REMOVE REVERSE RESTRICT PIN


    1. A01SDT4

      Using a T40 ''TORX'' socket wrench, remove the plug.

    2. A01SABJ

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

    3. A01SALD

      Remove the reverse restrict pin.

  15. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

    Click here

  16. REMOVE FRONT BEARING RETAINER


    1. A01SDN9

      Remove the 8 bolts.

    2. A01SBDZ

      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

    Click here

  18. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A01SE9C

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

  19. REMOVE COUNTER GEAR FRONT BEARING SNAP RING


    1. A01SDHQ

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01SD3I

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

  21. REMOVE TRANSMISSION MAGNET


    1. A01SALF

      Remove the transmission magnet from the intermediate plate.

  22. SECURE INTERMEDIATE PLATE


    1. A01SD7V

      Secure the intermediate plate in a vise between aluminum plates.

  23. REMOVE SHIFT DETENT BALL PLUG


    1. A01SBXDC03
      *a for Type A
      *b for Type B

      Remove the shift detent ball plug from the intermediate plate.


      1. for Type A:

        Using a T40 ''TORX'' socket wrench, remove the shift detent ball plug from the intermediate plate.

      2. for Type B:

        Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the intermediate plate.

    2. A01SCEB

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

    3. A01SE0TC02
      *a for Type A
      *b for Type B

      Remove the shift detent ball plug from the intermediate plate.


      1. for Type A:

        Using a T40 ''TORX'' socket wrench, remove the 2 shift detent ball plugs from the intermediate plate.

      2. for Type B:

        Using a 6 mm hexagon socket wrench, remove the 2 shift detent ball plugs from the intermediate plate.

    4. A01SBPH

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

  24. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01SDW8

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

      Note

      Use a cloth to prevent the shift fork shaft snap ring from flying off.

    2. A01SDAH

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

    3. A01SAAW

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

    4. A01SBFZ

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

    5. A01SAQS

      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. A01SDUH

      Using 2 screwdrivers and a hammer, tap off the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

      Note

      Use a cloth to prevent the shift fork shaft snap ring from flying off.

    2. A01SB7P

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

    3. A01SBHK

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

    4. A01SBO3

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

    5. A01SETF

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

  26. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01SDY2

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

    2. A01SDQR

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

      Note

      Use a cloth to prevent the shift fork shaft snap ring from flying off.

    3. A01SE18

      Using a magnet hand, remove the No. 1 shift interlock roller from the reverse shift fork.

    4. A01SBR2

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

  27. REMOVE REVERSE SHIFT FORK


    1. A01SC8S

      Remove the reverse shift fork from the reverse shift arm.

  28. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01SAUI

      Remove the torsion spring from the reverse shift arm bracket.

    2. A01SE82

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

    3. A01SETY

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

    4. A01SDW3

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

  29. REMOVE SPEEDOMETER DRIVE GEAR


    1. A01SDMJ

      Using snap ring pliers, remove the snap ring.

    2. Remove the speedmeter drive gear.

    3. Using a magnet hand, remove the steel ball.

    4. Using snap ring pliers, remove the snap ring.

  30. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01SC0D

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

    2. A01SEKVN01

      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 )

  31. INSPECT COUNTERSHAFT 5TH GEAR THRUST CLEARANCE

    Click here

  32. INSPECT COUNTERSHAFT 5TH GEAR RADIAL CLEARANCE

    Click here

  33. REMOVE COUNTER SHAFT REAR SNAP RING


    1. A01SEPC

      Using 2 screwdrivers and a hammer, tap off the counter shaft rear snap ring from the countershaft 5th gear.

  34. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01SB8O

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

  35. REMOVE COUNTERSHAFT 5TH GEAR


    1. A01SBT9N03

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

      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. A01SADC

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

  37. REMOVE NO. 3 SYNCHRONIZER RING


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

  38. REMOVE COUNTER 5TH GEAR BEARING


    1. A01SCW6

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

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. A01SDWV

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

    2. A01SE7D

      Remove the No. 3 synchromesh shifting key spring and 2 No. 3 synchromesh shifting keys from the countershaft 5th gear.

  40. REMOVE 5TH GEAR THRUST WASHER


    1. A01SALP

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

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01SAQB

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

  42. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A01SB0Y

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

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01SE5X

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

  44. REMOVE COUNTER SHAFT REAR BEARING


    1. A01SBI2

      Using a snap ring expander, remove the snap ring.

    2. A01SBGWN01

      Using SST, remove the counter shaft rear 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 counter shaft rear bearing while tapping the tip of the counter gear so that the counter gear does not hit the side wall of the output shaft gear by being pushed forward.

  45. REMOVE COUNTER GEAR


    1. A01SBNB

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT


    1. A01SB8H

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

      Note

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

  47. INSPECT NO. 2 SYNCHRONIZER RING

    Click here

  48. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01SAAJ

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

  49. REMOVE OUTPUT SHAFT


    1. A01SCU5

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

  50. REMOVE STRAIGHT PIN

    Note

    If a straight pin is deformed or its threads are damaged, replace it.

  51. REMOVE RING PIN

    Note

    If a ring pin is deformed or its threads are damaged, replace it.

  52. INSPECT NO. 3 SYNCHRONIZER RING

    Click here

  53. INSPECT NO. 3 TRANSMISSION HUB SLEEVE

    Click here

  54. INSPECT COUNTERSHAFT 5TH GEAR

    Click here

  55. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

    Click here