MANUAL TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. B003S6D

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

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. B003QAZ

      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. B003S9ZC01
      *A for 2TR-FE
      *B for 5L-E

      Remove the 9 bolts.

    2. B003NS0

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

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  8. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. B003QFZ

      Remove the 2 reverse restrict pin assemblies from the transfer adapter sub-assembly.

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


    1. B003NN9

      Remove the 4 bolts.

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

    3. Remove the control shift lever retainer gasket.

  10. REMOVE TRANSFER ADAPTER SUB-ASSEMBLY


    1. B003PYA

      Remove the 10 bolts and 2 wire harness brackets.

    2. B003MRL

      Using a brass bar and a hammer, tap out the transfer adapter sub-assembly from the manual transmission case.

  11. REMOVE SHIFT AND SELECT LEVER


    1. B003QHJ

      Remove the bolt from the shift lever housing.

    2. B003RAR

      Remove the shift and select lever and the shift lever housing from the transfer adapter sub-assembly.

  12. REMOVE TRANSFER OIL RECEIVER PIPE


    1. B003LSA

      Remove the transfer oil receiver pipe from the transfer adapter sub-assembly.

  13. REMOVE REVERSE RESTRICT PIN


    1. B003JLZ

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

    2. B003LCS

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

    3. B003S7U

      Remove the reverse restrict pin.

  14. REMOVE TRANSFER ADAPTER OIL SEAL

    Click here

  15. REMOVE FRONT BEARING RETAINER


    1. B003OAG

      Remove the 8 bolts.

    2. B003J2X

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

  16. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    Click here

  17. REMOVE FRONT BEARING SHAFT SNAP RING


    1. B003NO6

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

  18. REMOVE COUNTER GEAR FRONT BEARING SNAP RING


    1. B003OCX

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. B003QQ7

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

  20. REMOVE TRANSMISSION MAGNET


    1. B003MY0

      Remove the transmission magnet from the intermediate plate.

  21. SECURE INTERMEDIATE PLATE


    1. B003R7U

      Secure the intermediate plate in a vise between aluminum plates.

  22. REMOVE SHIFT DETENT BALL PLUG


    1. B003KYBC03
      *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. B003ONR

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

    3. B003O1FC02
      *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. B003KBN

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

  23. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. B003PPE

      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. B003L78

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

    3. B003P7Y

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

    4. B003LXW

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

    5. B003RGD

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

  24. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. B003NO3

      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. B003MEN

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

    3. B003S2J

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

    4. B003O3F

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

    5. B003NWE

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

  25. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. B003O29

      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. B003N1G

      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. B003LI5

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

    4. B003PB4

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

  26. REMOVE REVERSE SHIFT FORK


    1. B003K1U

      Remove the reverse shift fork from the reverse shift arm.

  27. REMOVE REVERSE SHIFT ARM BRACKET


    1. B003NZP

      Remove the torsion spring from the reverse shift arm bracket.

    2. B003JYB

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

    3. B003K7P

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

    4. B003RXZ

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

  28. REMOVE OUTPUT SHAFT REAR BEARING


    1. B003JQW

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

    2. B003PUZC01
      *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 )

  29. INSPECT COUNTERSHAFT 5TH GEAR THRUST CLEARANCE

    Click here

  30. INSPECT COUNTERSHAFT 5TH GEAR RADIAL CLEARANCE

    Click here

  31. REMOVE COUNTER SHAFT REAR SNAP RING


    1. B003SFV

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

  32. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. B003RNH

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

  33. REMOVE COUNTERSHAFT 5TH GEAR


    1. B003ROKN01

      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 counter gear.

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

  34. REMOVE NO. 5 GEAR SPLINE PIECE


    1. B003KYHC02
      *1 No. 5 Gear Spline Piece
      *2 No. 3 Synchronizer Ring
      *3 Countershaft 5th Gear

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

  35. REMOVE NO. 3 SYNCHRONIZER RING


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

  36. REMOVE COUNTER 5TH GEAR BEARING


    1. B003KJ3

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

  37. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. B003J66

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

    2. B003K75C02
      *1 No. 3 Synchromesh Shifting Key Spring
      *2 No. 3 Synchromesh Shifting Key
      *3 Countershaft 5th Gear

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

  38. REMOVE 5TH GEAR THRUST WASHER


    1. B003KOV

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

  39. REMOVE 5TH GEAR THRUST WASHER PIN


    1. B003OK1

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

  40. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. B003PIO

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

  41. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. B003LA6

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

  42. REMOVE COUNTER SHAFT REAR BEARING


    1. B003ONB

      Using a snap ring expander, remove the snap ring.

    2. B003OURN03

      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.

  43. REMOVE COUNTER GEAR


    1. B003NCT

      Remove the counter gear from the intermediate plate.

  44. REMOVE INPUT SHAFT


    1. B003M8S

      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.

  45. INSPECT NO. 2 SYNCHRONIZER RING

    Click here

  46. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. B003PQB

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

  47. REMOVE OUTPUT SHAFT


    1. B003N49

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

  48. REMOVE STRAIGHT PIN

    Note

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

  49. REMOVE RING PIN

    Note

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

  50. INSPECT NO. 3 SYNCHRONIZER RING

    Click here

  51. INSPECT NO. 3 TRANSMISSION HUB SLEEVE

    Click here

  52. INSPECT COUNTERSHAFT 5TH GEAR

    Click here

  53. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

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