MANUAL TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  2. REMOVE RELEASE FORK SUPPORT

    Click here

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  4. REMOVE BACK-UP LIGHT SWITCH BRACKET


    1. B003LDB

      Remove the 3 bolts and back-up light switch brackets.

  5. REMOVE TRANSMISSION REVOLUTION SENSOR (w/ Intelligent Manual Transmission Switch)

    Click here

  6. REMOVE NEUTRAL POSITION SWITCH

    w/ Downhill Assist Control:

    Click here

  7. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. B003SCM

      Remove the manual transmission filler plugs, drain plug sub-assembly and 2 gaskets from the manual transmission case sub-assembly.

    2. Using a 10 mm hexagon wrench, remove the with head straight screw plug from the rear transmission case.

  8. REMOVE SHAFT DETENT BALL


    1. B003JMC

      Using a 6 mm hexagon wrench, remove the 4 shift detent ball plugs from the rear transmission case.

    2. Remove the 4 shift detent ball compression springs and 4 shift detent balls from the rear transmission case.

  9. REMOVE LOCK BALL PIN


    1. B003RYS

      Using a 10 mm hexagon wrench, remove the No. 2 with head straight screw plug from the rear transmission case.

    2. Remove the lock ball pin and shift and select lever spring from the rear transmission case.

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


    1. B003O1Y

      Remove the 4 bolts and then remove the floor shift control shift lever retainer sub-assembly and control shift lever retainer gasket from the rear transmission case sub-assembly.

  11. REMOVE SHIFT LEVER HOUSING


    1. B003OMZ

      Remove the bolt and shift lever housing.

      Note

      Do not damage the sealing surface of the control shift lever retainer sub-assembly

  12. REMOVE MANUAL TRANSMISSION CASE COVER


    1. B003KOS

      Remove the 4 bolts and manual transmission case cover from the rear transmission case.

  13. UNSTAKE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B003QSA

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

  14. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B003R1ZC03
      *1 Input Shaft

      Engage the gear, and then secure the input shaft using SST.

      SST
      09322-35010   ( 09322-03010, 09322-03020, 09322-03030, 90105-12087, 90170-12030, 94622-51200 )

      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.

    2. B003JS8N01

      Using SST, remove the manual transmission output shaft rear set nut from the output shaft.

      SST
      09326-35010   ( 09326-03010 )

  15. REMOVE CLUTCH HOUSING


    1. B003O6R

      Remove the 10 bolts.

    2. Using a plastic-faced hammer, carefully tap off the clutch housing to remove it.

  16. REMOVE FRONT BEARING RETAINER


    1. B003O1H

      Remove the 11 bolts.

    2. B003R77

      Using a screwdriver wrapped in protective tape, remove the front bearing retainer by prying the points in the illustration.

      Note


      • Do not damage the sealing surface of the clutch housing and manual transmission case sub-assembly.

      • Do not damage the sealing surface of the front bearing retainer and manual transmission case sub-assembly.

  17. REMOVE NO. 1 OIL RECEIVER PIPE


    1. Remove the No. 1 oil receiver pipe from the front bearing retainer.

  18. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL

    Click here

  19. REMOVE COUNTER GEAR SHAFT NUT


    1. B003QW1

      Using a chisel and hammer, unstake the counter gear shaft nut.

    2. B003LZFN01

      Using SST, hold the output shaft.

      SST
      09326-35010   ( 09326-03010 )
      09326-71030

    3. Using a 41 mm socket wrench, remove the counter gear shaft nut.

  20. REMOVE INPUT SHAFT SNAP RING


    1. B003L21

      Using snap ring pliers, remove the input shaft snap ring.

  21. REMOVE FRONT BEARING SHAFT SNAP RING


    1. B003MEY

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

  22. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. B003JZK

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

  23. REMOVE MANUAL TRANSMISSION CASE SUB-ASSEMBLY

    CAUTION:

    Since the manual transmission unit is very heavy, 2 people are needed to remove the manual transmission case sub-assembly.


    1. B003LM6

      Remove the 12 bolts.

    2. B003M02

      In order to prevent the reverse idler gear from falling when removing the transmission case, set the manual transmission assembly on its side so that the installation hole of the reverse idler gear stopper bolt is facing upward as shown in the illustration.

    3. B003OK8C01
      *1 Straight Pin
      *a Protective Tape

      Using a screwdriver wrapped in protective tape, separate the transmission case sub-assembly and intermediate plate by prying at the points shown in the illustration.

      Note

      Do not damage the sealing surfaces of the manual transmission case sub-assembly and transmission intermediate plate.

    4. B003MMG

      Place wooden blocks or other objects underneath the rear transmission case to securely support it as shown in the illustration.

    5. Remove the manual transmission case sub-assembly from the rear transmission case.

  24. REMOVE REVERSE IDLER GEAR

    CAUTION:

    Since the manual transmission is very heavy, perform these procedures with 2 people. While one person is removing the reverse idler gear, have the other person hold the transmission in place.


    1. B003P4R

      Remove the reverse idler gear and front oil receiver from the transmission unit.

    2. Remove the No. 2 oil receiver from the reverse idler gear shaft.

    3. B003QWW

      Remove the reverse idler gear bearing and reverse idler gear from the reverse idler gear shaft.

  25. REMOVE SHIFT AND SELECT LEVER SHAFT SUB-ASSEMBLY


    1. B003MU0

      Remove the shift and select lever shaft sub-assembly from the transmission unit.

      CAUTION:

      Since the manual transmission is very heavy, perform these procedures with 2 people. While one person is removing the shift and select shaft, have the other person hold the transmission in place.

  26. REMOVE SHIFT INTERLOCK PLATE STOPPER


    1. B003M81

      Remove the 2 bolts and shift interlock plate stopper from the transmission unit.

      CAUTION:

      Since the manual transmission is very heavy, perform these procedures with 2 people. While one person is removing the shift interlock plate stopper, have the other person hold the transmission in place.

  27. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. B003M2N

      Remove the 2 bolts and transmission oil separator sub-assembly (front side).

      CAUTION:

      Since the manual transmission is very heavy, perform these procedures with 2 people. While one person is removing the manual transmission oil separator sub-assembly, have the other person hold the transmission in place.

  28. REMOVE TRANSMISSION MAGNET


    1. B003J2U

      Remove the transmission magnet from the transmission intermediate plate.

      CAUTION:

      Since the manual transmission is very heavy, perform these procedures with 2 people. While one person is removing the manual transmission magnet, have the other person hold the transmission in place.

  29. REMOVE REAR TRANSMISSION CASE


    1. B003KYFN01

      Using SST, set the transmission unit.

      SST
      09310-71010

      CAUTION:

      Since the manual transmission unit is very heavy, 2 people are needed to set the transmission unit.

    2. B003MW1N01

      Stand the manual transmission upright as shown in the illustration.

      CAUTION:

      Since the manual transmission unit is very heavy, 2 people are needed to stand the manual transmission upright as shown in the illustration.

    3. B003MZ0

      Remove the rear output shaft bearing.

    4. B003K4J

      Remove the rear transmission case and intermediate plate.

    5. Remove the intermediate plate from the rear transmission case.

    6. B003JEF

      Remove the transmission oil separator sub-assembly (rear side).

  30. REMOVE NO. 3 OIL RECEIVER PIPE


    1. B003J6T

      Remove the No. 3 oil receiver pipe from the rear transmission case.

  31. REMOVE SHIFT FORK AND SHIFT FORK SHAFT ASSEMBLY


    1. B003PXYC01
      B003OFB Remove in this Direction

      Move the No. 2 hub sleeve as shown in the illustration and remove the No. 3 gear shift fork from SST as shown in the illustration.

    2. B003NJ4C02
      B003OFB Remove in this Direction

      Slide the No. 3 gear shift fork from position 1 to 2 and then remove the No. 3 gear shift fork together with the No. 3 gear shift fork shaft.

    3. B003PHLC01
      *1 No. 2 Transmission Hub Sleeve
      *2 No. 1 Transmission Hub Sleeve
      *3 No. 4 Transmission Hub Sleeve
      B003OFB Remove in this Direction

      Slide the No. 2 and No. 1 hub sleeves as shown in the illustration.

    4. Remove the bolt from the No. 4 gear shift fork, and then slide the No. 4 gear shift fork shaft as shown in the illustration.

    5. B003KZAC01
      B003OFB Remove in this Direction

      Move the shift fork and shift fork shaft assembly as shown in the illustration.

      Note

      Move the 3 shift fork shafts together.

    6. B003OSU

      Remove the shift fork and shift fork shaft sub-assembly from the counter gear.

      Note

      Do not drop the No. 4 gear shift fork.

    7. B003SG0

      Remove the No. 4 gear shift fork.

  32. REMOVE OUTPUT SHAFT


    1. B003SAWC01
      *1 Input Shaft
      *2 Counter Gear

      Expand SST to the left and right.

    2. B003QZ7

      Remove the output shaft from the transmission unit.

    3. Remove the output shaft spacer and rear output shaft bearing shim.

  33. REMOVE INPUT SHAFT BEARING


    1. B003M9B

      Remove the input shaft bearing from the input shaft.

  34. REMOVE NO. 4 SYNCHRONIZER RING


    1. B003P6O

      Remove the No. 4 synchronizer ring from the input shaft.

  35. REMOVE INPUT SHAFT


    1. Remove the input shaft from SST.

  36. REMOVE COUNTER GEAR


    1. Remove the counter gear from SST.

  37. REMOVE COUNTER GEAR REAR BEARING OR ROLLER


    1. B003MAN

      Remove the bolt and bearing lock plate.

    2. B003K6ZC01
      *a Groove of the Rear Transmission Case

      Using SST, remove the counter gear rear bearing or roller (outer) from the rear transmission case.

      SST
      09308-00010

      Note

      Do not damage the contact surfaces of the rear transmission case.

      Tech Tips

      Align the groove of the rear transmission case with the claws of SST.

  38. REMOVE FRONT OUTPUT SHAFT BEARING


    1. B003M0VC01
      *a Groove of the Rear Transmission Case

      Using SST, remove the front output shaft bearing (outer race) from the rear transmission case.

      SST
      09308-00010

      Note

      Do not damage the contact surfaces of the rear transmission case.

      Tech Tips

      Align the groove of the rear transmission case with the claws of SST.

  39. REMOVE REAR OUTPUT SHAFT BEARING


    1. B003JHMC01
      *a Groove of the Rear Transmission Case

      Using SST, remove the rear output shaft bearing (outer) from the rear transmission case.

      SST
      09308-00010

      Note

      Do not damage the contact surfaces of the rear transmission case.

      Tech Tips

      Align the groove of the rear transmission case with the claws of SST.

  40. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. B003OHGN01

      Using SST, remove the shift and select lever shaft needle roller bearing from the rear transmission case sub-assembly.

      SST
      09950-70010   ( 09951-07200 )
      09950-60010   ( 09951-00230 )

  41. REMOVE TRANSMISSION CASE PLUG


    1. B003QO5N02

      Using SST, remove the transmission case plug from the rear transmission case sub-assembly.

      SST
      09950-70010   ( 09951-07200 )
      09950-60010   ( 09951-00230 )

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. B003OC4C02
      *a Turn
      *b Hold

      Using SST, remove the 2 shift fork shaft bearings (rear side) from the rear transmission case sub-assembly.

      SST
      09319-60020

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. B003O6CC01
      *a Turn
      *b Hold

      Using SST, remove the shift and select lever shaft needle roller bearing (front side) from the front transmission case sub-assembly.

      SST
      09319-60020

  44. REMOVE SHIFT FORK SHAFT BEARING


    1. B003L4JC02
      *a Turn
      *b Hold

      Using SST, remove the 2 shift fork shaft bearings (front side) from the front transmission case sub-assembly.

      SST
      09319-60020

  45. REMOVE SHIFT AND SELECT LEVER SHAFT


    1. B003OGN

      Using a snap ring expander, remove the e-ring from the shift and select lever shaft.

    2. B003KTZ

      Remove the bolt from the inner select lever.

    3. B003Q7I

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

    4. Remove the shift interlock plate sub-assembly and inner select lever (shift and select cam, No. 2 lock ball pin and select return No. 1 compression spring) from the shift and select lever shaft.

    5. B003MRZ

      Remove the shift and select cam, No. 2 lack ball pin and select return No. 1 compression spring from the inner select lever.

    6. B003KQQ

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

      Tech Tips

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

    7. Remove the shift arm pivot and shift arm from the shift interlock plate sub-assembly.

  46. REMOVE NEEDLE ROLLER BEARING


    1. B003LJWC01
      *1 Needle Roller Bearing
      *2 Shift Arm

      Using SST and a press, remove the needle roller bearing from the shift arm.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      09527-20011

  47. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. B003L2T

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

    2. Remove the No. 2 gear shift fork shaft from the No. 1 gear shift fork head.

    3. B003QL3

      Place a cloth on 2 V-blocks, set the No. 2 gear shift fork shaft on the cloth, and then hold the shaft in place as shown in the illustration.

      CAUTION:


      • Perform this procedure with 2 people.

      • Make sure to protect the gear shift fork shaft with a cloth before performing this procedure. If the gear shift fork shaft is damaged, shifting operations will worsen.

      • Firmly secure the gear shift fork shaft.

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

    5. Remove the No. 2 gear shift head from the No. 2 gear shift fork shaft.

  48. REMOVE NO. 4 GEAR SHIFT FORK SHAFT


    1. Remove the No. 4 gear shift fork from the No. 4 gear shift fork shaft.

    2. B003M2E

      Place a cloth on 2 V-blocks, set the No. 4 gear shift fork shaft on the cloth, and then hold the shaft in place as shown in the illustration.

      CAUTION:


      • Perform this procedure with 2 people.

      • Make sure to protect the gear shift fork shaft with a cloth before performing this procedure. If the gear shift fork shaft is damaged, shifting operations will worsen.

      • Firmly secure the gear shift fork shaft.

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

    4. Remove the No. 4 gear shift head from the No. 4 gear shift fork shaft.

  49. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. B003KMG

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

    2. B003OZO

      Place a cloth on 2 V-blocks, set the No. 1 gear shift fork shaft on the cloth, and then hold the shaft in place as shown in the illustration.

      CAUTION:


      • Perform this procedure with 2 people.

      • Make sure to protect the gear shift fork shaft with a cloth before performing this procedure. If the gear shift fork shaft is damaged, shifting operations will worsen.

      • Firmly secure the gear shift fork shaft.

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

    4. Remove the No. 1 gear shift head from the No. 1 gear shift fork shaft.

  50. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. B003M15

      Remove the bolt and No. 3 gear shift fork from the No. 3 gear shift fork shaft.