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. B0068WQ

      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/ Stop And Start System)

    Click here

  7. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. B0068H7

      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 straight screw plug with head from the rear transmission case.

  8. REMOVE SHAFT DETENT BALL


    1. B00699Z

      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. B006934

      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. B0068N9

      Remove the 4 bolts and then remove the floor shift control shift lever retainer sub-assembly and control shift lever retainer gasket from the extension housing sub-assembly.

  11. REMOVE SHIFT LEVER HOUSING


    1. B0068PC

      Remove the bolt and shift lever housing.

      Note

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

  12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. B0068OZ

      Remove the 8 bolts and extension housing sub-assembly.

  13. REMOVE NO. 4 OIL RECEIVER PIPE


    1. B0068TO

      Remove the No. 4 oil receiver pipe from the extension housing sub-assembly.

  14. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

    Click here

  15. REMOVE TRANSMISSION OIL SEPARATOR


    1. B00698X

      Remove the 2 bolts and transmission oil separator from the rear transmission case.

  16. REMOVE TRANSMISSION OIL RUNNER


    1. B0068UR

      Using a snap ring expander, remove the snap ring from the output shaft sub-assembly.

    2. Remove the transmission oil runner from the output shaft sub-assembly.

  17. UNSTAKE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B0068DC

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

  18. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B0068WZC03
      *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. B0068CWN01

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

      SST
      09326-35020

  19. REMOVE CLUTCH HOUSING


    1. B0068M6

      Remove the 10 bolts.

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

  20. REMOVE FRONT BEARING RETAINER


    1. B0068HW

      Remove the 11 bolts.

    2. B0068SR

      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.

  21. REMOVE NO. 1 OIL RECEIVER PIPE


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

  22. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL

    Click here

  23. REMOVE COUNTER GEAR SHAFT NUT


    1. B0068Z4

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

    2. B0068EXN01

      Using SST, hold the output shaft.

      SST
      09326-35020

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

  24. REMOVE INPUT SHAFT SHAFT SNAP RING


    1. B0068RL

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

  25. REMOVE FRONT BEARING SHAFT SNAP RING


    1. B0069DY

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

  26. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. B00699G

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

  27. 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. B00691L

      Remove the 12 bolts.

    2. B0068TK

      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. B00695JC01
      *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. B0068JG

      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.

  28. 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. B0069D4

      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. B0068GZ

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

  29. REMOVE SHIFT AND SELECT LEVER SHAFT SUB-ASSEMBLY


    1. B0068T4

      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.

  30. REMOVE SHIFT INTERLOCK PLATE STOPPER


    1. B00697B

      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.

  31. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. B0069CO

      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.

  32. REMOVE TRANSMISSION MAGNET


    1. B0068US

      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.

  33. REMOVE REAR TRANSMISSION CASE


    1. B0069A3N01

      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. B0068YUN01

      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. B0068X0

      Remove the rear output shaft bearing.

    4. B0069A1

      Remove the rear transmission case and intermediate plate.

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

    6. B00690V

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

  34. REMOVE NO. 3 OIL RECEIVER PIPE


    1. B0068WN

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

  35. REMOVE SHIFT FORK AND SHIFT FORK SHAFT ASSEMBLY


    1. B0068WUC01
      B0069FO 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. B00697FC02
      B0069FO 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. B0068S5C01
      *1 No. 2 Transmission Hub Sleeve
      *2 No. 1 Transmission Hub Sleeve
      *3 No. 4 Transmission Hub Sleeve
      B0069FO 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. B0068P9C01
      B0069FO 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. B0068PX

      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. B0068GT

      Remove the No. 4 gear shift fork.

  36. REMOVE OUTPUT SHAFT


    1. B00694JC01
      *1 Input Shaft
      *2 Counter Gear

      Expand SST to the left and right.

    2. B006959

      Remove the output shaft from the transmission unit.

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

  37. REMOVE INPUT SHAFT BEARING


    1. B00691C

      Remove the input shaft bearing from the input shaft.

  38. REMOVE NO. 4 SYNCHRONIZER RING


    1. B0069FJ

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

  39. REMOVE INPUT SHAFT


    1. Remove the input shaft from SST.

  40. REMOVE COUNTER GEAR


    1. Remove the counter gear from SST.

  41. REMOVE REAR COUNTER GEAR BEARING OR ROLLER


    1. B0069EO

      Remove the bolt and bearing lock plate.

    2. B00690MC01
      *a Groove of the Rear Transmission Case

      Using SST, remove the rear counter gear 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.

  42. REMOVE FRONT OUTPUT SHAFT BEARING


    1. B0068A9C01
      *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.

  43. REMOVE REAR OUTPUT SHAFT BEARING


    1. B00692GC01
      *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.

  44. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. B0068UIC01
      *a Turn
      *b Hold

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

      SST
      09319-60020

  45. REMOVE SHIFT FORK SHAFT BEARING


    1. B0068IFC02
      *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

  46. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. B0068V2C01
      *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

  47. REMOVE SHIFT FORK SHAFT BEARING


    1. B0068VPC02
      *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

  48. REMOVE SHIFT AND SELECT LEVER SHAFT


    1. B0068GR

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

    2. B0068S9

      Remove the bolt from the inner select lever.

    3. B0069FH

      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. B0068HU

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

    6. B0068H3

      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 together with the needle roller bearing from the shift interlock plate sub-assembly.

  49. REMOVE NEEDLE ROLLER BEARING


    1. B006944C01
      *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

  50. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. B006983

      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. B0068KA

      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.

  51. REMOVE NO. 4 GEAR SHIFT FORK SHAFT


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

    2. B006987

      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.

  52. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. B0068J2

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

    2. B00690Y

      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.

  53. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. B0069D3

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