MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY (for 1GR-FE)

    A0158KD

    1. Loosen the hose clamp, and remove the breather hose.

  2. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY (for 1VD-FTV)

    A0159FO

    1. Remove the wire harness clamp.

    2. Loosen the hose clamp, and remove the breather hose.

  3. REMOVE CLUTCH HOUSING

    A0155SUE03

    1. Remove the 10 bolts and clutch housing.

  4. REMOVE FILLER PLUG

    A0158KM

    1. Remove the filler plug.

    2. Remove the gasket from the filler plug.

  5. REMOVE DRAIN PLUG

    A0156UO

    1. Remove the drain plug.

    2. Remove the gasket from the drain plug.

  6. REMOVE MANUAL TRANSMISSION CASE PLUG

    A0155A0

    1. Using a T55 "TORX" socket wrench, remove the transmission case plug.

    2. Remove the gasket from the transmission case plug.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    A0156WXE01

    1. Disconnect the wire harness clamp.

    2. Using SST, remove the back-up light switch and gasket.

      SST
      09817-16011

  8. REMOVE SHIFT POSITION SWITCH (for 1VD-FTV)

    A01587LE01

    1. Disconnect the wire harness clamp.

    2. Using SST, remove the shift position switch and gasket.

      SST
      09817-16011

  9. REMOVE CONTROL SHAFT COVER

    A01582X

    1. Remove the 6 bolts and control shaft cover.

  10. REMOVE REVERSE RESTRICT PIN ASSEMBLY

    A0157EC

    1. Remove the 2 restrict pins.

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

    A0156NK

    1. Remove the 4 bolts.

    2. A0156VA

      Using a plastic-faced hammer, remove the floor shift control shift lever retainer.

  12. REMOVE NO. 1 REVERSE RESTRICT PIN

    A015DK1

    1. Remove the slotted pin.

    2. A015AE4

      Remove the No. 1 reverse restrict pin and spring.

  13. REMOVE TRANSMISSION OIL PUMP COVER

    A015DX9

    1. Remove the 5 bolts and oil pump cover.

    2. A01558M

      Using a magnet hand, remove the 2 pins.

    3. Remove the oil pump cover O-ring from the oil pump cover.

  14. REMOVE TRANSMISSION OIL PUMP COVER OIL SEAL

    A0157HLE01

    1. Using a screwdriver, pry out the oil pump cover oil seal.

      Note

      Be careful not to damage the oil seal and oil pump cover contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  15. REMOVE FRONT BEARING RETAINER (MTM)

    A0156BM

    1. Remove the 8 bolts and front bearing retainer.

  16. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A0156K8E01

    1. Using a screwdriver, pry out the oil seal.

      Note

      Be careful not to damage the oil seal and front bearing retainer contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  17. REMOVE SHIFT AND SELECT LEVER SHAFT

    A0159PR

    1. Using a 14 mm hexagon wrench, remove the interlock hole plug.

    2. A0157M5E02

      Remove the 3 bolts, shift and select lever shaft, shift and select lever and shift lever housing.

  18. REMOVE TRANSFER ADAPTER SUB-ASSEMBLY

    A0158OZ

    1. Remove the 11 bolts and transfer adapter.

  19. REMOVE TRANSFER ADAPTER STRAIGHT PIN AND RING PIN

    A015CINE01

    1. Remove the 4 straight pins from the transfer adapter.

    2. Remove the 2 ring pins from the transfer adapter.

  20. REMOVE TRANSFER ADAPTER PLUG

    A0157HG

    1. Using a T40 "TORX" socket wrench, remove the transfer adapter plug.

  21. REMOVE MANUAL TRANSMISSION OIL STRAINER SUB-ASSEMBLY

    A0159EFE01

    1. Remove the 2 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  22. REMOVE TRANSMISSION MAGNET

    A0157FO

    1. Remove the transmission magnet.

  23. REMOVE NO. 2 REVERSE IDLER THRUST WASHER

    A01589N

    1. Remove the thrust washer.

  24. REMOVE REVERSE IDLER GEAR


    1. Remove the reverse idler gear.

  25. REMOVE REVERSE IDLER GEAR BUSH OR BEARING


    1. Remove the bearing.

  26. REMOVE REVERSE IDLER THRUST WASHER


    1. Remove the thrust washer.

  27. REMOVE REVERSE IDLER GEAR SHAFT


    1. Remove the reverse idler gear shaft.

  28. REMOVE REVERSE IDLER GEAR SHAFT WOODRUFF KEY


    1. Remove the woodruff key from the reverse idler gear shaft.

  29. REMOVE MANUAL TRANSMISSION CASE SUB-ASSEMBLY

    A015CDK

    1. Using a snap ring expander, remove the 2 snap rings from the input shaft and counter gear.

    2. A0158XG

      Using a brass bar and hammer, carefully tap the transmission case.

    3. Remove the transmission case from the intermediate plate.

  30. REMOVE NO. 1 OIL RECEIVER PIPE (MTM)

    A015C3AE01

    1. Remove the 2 bolts and oil receiver pipe from the transmission case.

  31. REMOVE TRANSFER ADAPTER STRAIGHT PIN

    A0156OCE01

    1. Remove the 4 straight pins from the transmission case.

  32. REMOVE INTERMEDIATE PLATE STRAIGHT PIN

    A015DXEE01

    1. Remove the 4 straight pins from the intermediate plate.

  33. REMOVE MANUAL TRANSMISSION CASE RECEIVER


    1. A015DDR

      Remove the 3 bolts and oil receiver from the intermediate plate.

  34. REMOVE SHIFT DETENT BALL PLUG

    A015D9F

    1. Using a T40 "TORX" socket wrench, remove the 4 ball plugs.

    2. Using a magnet hand, remove the 4 springs and 4 balls.

  35. REMOVE SHIFT FORK SHAFT SNAP RING

    A0156MT

    1. Using 2 screwdrivers and a hammer, tap out the 4 snap rings.

      Tech Tips

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

  36. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

    A0157CQ

    1. Remove the No. 4 gear shift fork set bolt.

    2. A0158J6

      Remove the No. 4 gear shift fork shaft and 2 balls.

  37. REMOVE REVERSE SHIFT FORK


    1. Remove the reverse shift fork.

  38. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    A0155WO

    1. Using a magnet hand, remove the ball.

    2. A0159TU

      Remove the No. 3 gear shift fork set bolt.

    3. Remove the No. 3 shift gear fork shaft and reverse shift head.

    4. A015D68

      Using a magnet hand, remove the interlock pin from the No. 3 gear shift fork shaft.

  39. REMOVE NO. 3 GEAR SHIFT FORK


    1. Remove the No. 3 gear shift fork.

  40. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

    A015A5V

    1. Using a magnet hand, remove the interlock pin.

    2. A0159KY

      Remove the No. 1 gear shift fork set bolt.

    3. Remove the No. 1 gear shift fork shaft.

    4. A015757

      Using a magnet hand, remove the interlock pin from the No. 1 gear shift fork shaft.

  41. REMOVE NO. 1 GEAR SHIFT FORK


    1. Remove the No. 1 gear shift fork.

  42. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    A0156AO

    1. Using a magnet hand, remove the interlock pin.

    2. A0156VF

      Remove the No. 2 gear shift fork set bolt.

    3. Remove the No. 2 gear shift fork shaft.

  43. REMOVE NO. 2 GEAR SHIFT FORK


    1. Remove the No. 2 gear shift fork.

  44. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

    A0155TX

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

      Tech Tips

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

  45. REMOVE NO. 4 TRANSMISSION CLUTCH HUB

    A015BFNE01

    1. Using SST, remove the No. 4 transmission clutch hub.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03080 )

  46. REMOVE REVERSE GEAR

    A015C61

    1. Remove the reverse synchronizer ring set and reverse gear.

  47. REMOVE REVERSE SYNCHRONIZER RING SET


    1. Remove the reverse synchronizer ring set from the reverse gear.

  48. REMOVE REVERSE GEAR BEARING


    1. Remove the reverse gear bearing.

  49. REMOVE NO. 1 TRANSMISSION HUB SLEEVE

    A015AB3E01

    1. Remove the No. 1 transmission hub sleeve, 3 shifting keys, and 3 springs from the No. 4 transmission clutch hub.

      Tech Tips

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

  50. REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER

    A01581A

    1. Remove the 4 bolts and rear bearing retainer.

  51. REMOVE COUNTER GEAR

    A0157B5

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

    2. A015BM9E01

      Using SST, remove the outer race.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04011, 09957-04010, 09958-04011 )

      Note

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

    3. A015C7F

      Using a screwdriver, remove the center bearing and counter gear.

  52. REMOVE INPUT SHAFT ASSEMBLY

    A015AWJ

    1. Remove the input shaft from the output shaft.

      Note

      Do not drop the input shaft bearing.

  53. REMOVE NO. 2 SYNCHRONIZER RING


    1. Remove the No. 2 synchronizer ring from the input shaft.

  54. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    A015BZH

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

  55. REMOVE OUTPUT SHAFT ASSEMBLY

    A015B9M

    1. Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.