MANUAL TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A00XGOTE01

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

  2. REMOVE DRAIN PLUG


    1. A00XGV5E01

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

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    A00OB0F

    1. Remove the release fork and release bearing from the clutch housing.

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    A00O2VJE01

    1. Remove the clip and release bearing from the release fork.

  5. REMOVE RELEASE FORK SUPPORT


    1. A00XHBOE01

      Remove the release fork support from the clutch housing.

  6. REMOVE CLUTCH RELEASE FORK BOOT


    1. A00XHXY

      Remove the release fork boot from the clutch housing.

  7. REMOVE CLUTCH HOUSING


    1. A00XIP3

      Remove the 9 bolts.

    2. A00XHE1E01

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

  8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00XIDME09

      Using SST, remove the back-up light switch and gasket from the manual transmission case.

      SST
      09817-16011
  9. REMOVE RESTRICT PIN


    1. A00XFFE

      Remove the 2 restrict pins from the transfer adapter.

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


    1. A00XD07

      Remove the 4 bolts and shift lever retainer.

    2. Remove the gasket.

  11. REMOVE TRANSFER ADAPTER


    1. A00XF7X

      Remove the 10 bolts.

    2. A00XGPP

      Using a brass bar and hammer, tap off the transfer adapter from the manual transmission case.

  12. REMOVE TRANSFER OIL RECEIVER PIPE


    1. A00XHATE01

      Remove the oil receiver pipe from the transfer adapter.

  13. REMOVE SHIFT AND SELECT LEVER


    1. A00XG5E

      Remove the bolt from the shift lever housing.

    2. A00XKHYE01
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Remove the shift and select lever and shift lever housing from the transfer adapter.

  14. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A00XIV0E01

      Using a T40 "TORX" socket wrench, remove the reverse restrict pin plug.

    2. A00XJKEE01

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

    3. A00XG7GE01

      Remove the restrict pin.

  15. REMOVE TRANSFER ADAPTER OIL SEAL


    1. A00XEJIE01

      Using a screwdriver and hammer, tap out the oil seal from the transfer adapter.

  16. REMOVE FRONT BEARING RETAINER


    1. A00XGJ8E01

      Remove the 8 bolts.

    2. A00XC8OE01

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

  17. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A00XCTOE01

      Secure the front bearing retainer in a vise between aluminum plates.

    2. Using SST, tap out the oil seal.

      SST
      09308-00010
  18. REMOVE FRONT BEARING SHAFT SNAP RING


    1. A00XI9VE01

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

  19. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING


    1. A00XDYCE01

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A00XIYDE01

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

  21. REMOVE TRANSMISSION MAGNET


    1. A00XIWXE01

      Remove the magnet from the intermediate plate.

  22. FIX INTERMEDIATE PLATE


    1. A00XFI4E01

      Secure the intermediate plate in a vise between aluminum plates.

  23. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A00XFANE01

      Using a T40 "TORX" socket wrench, remove the spring seat from the intermediate plate.

    2. A00XH8JE01

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

    3. A00XDG1E01

      Using a T40 "TORX" socket wrench, remove the 2 spring seats from the intermediate plate.

    4. A00XHZFE01

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

  24. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A00XEK3E01

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

      Note

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

    2. A00XDF5E01

      Remove the bolt from the No. 2 shift fork.

    3. A00XKBOE01

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

    4. A00XIHME01

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

    5. A00XIHWE01

      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. A00XK64E01

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

      Note

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

    2. A00XE2RE01

      Remove the bolt from the No. 1 shift fork.

    3. A00XG2DE01

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

    4. A00XGRPE01

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

    5. A00XF8VE01

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

  26. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A00XFFGE01

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

    2. A00XGH7E01

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

      Note

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

    3. A00XFCLE01

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

    4. A00XF8VE02

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

    5. A00XG9BE01

      Using a magnet hand, remove the reverse shift fork ball from the reverse shift fork.

  27. REMOVE NO. 4 GEAR SHIFT FORK SHAFT


    1. A00XDEFE01

      Using 2 screwdrivers and a hammer, tap off the snap ring from the No. 4 shift fork shaft.

      Note

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

    2. A00XI00E01

      Remove the No. 4 shift fork shaft from the intermediate plate.

      Note

      Cover the hole with a cloth to prevent the reverse shift fork ball from popping out.

    3. A00XFCOE01

      Using a magnet hand, remove the reverse shift fork ball and reverse shift fork return compression spring from the reverse shift fork.

  28. REMOVE REVERSE SHIFT FORK


    1. A00XFVLE01

      Remove the reverse shift fork with the reverse shift arm from the intermediate plate.

    2. A00XGJUE01

      Using a screwdriver, pry off the E-ring and remove the reverse shift fork from the reverse shift arm.

      Note

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

  29. REMOVE REVERSE SHIFT ARM BRACKET


    1. A00XE62E03

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

  30. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING (for Rear Bearing Side)


    1. A00XG6UE01

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

      Note

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

  31. REMOVE OUTPUT SHAFT REAR BEARING


    1. A00XD2WE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the 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 )
  32. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE


    1. A00XJXCE01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00393 to 0.0137 in.)

      • If the clearance is not as specified, replace the counter 5th gear.

  33. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE


    1. A00XIUVE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000590 to 0.00267 in.)

      • If the clearance is not as specified, replace the counter 5th gear bearing with a new one.

  34. REMOVE COUNTER GEAR REAR SHAFT SNAP RING


    1. A00XJZ4E01

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

      Note

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

  35. REMOVE NO. 5 GEAR SPLINE PIECE


    1. A00XCB1E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the gear spline piece from the counter 5th gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010 )
  36. REMOVE OUTER NO. 3 SYNCHRONIZER RING


    1. A00XE0LE01

      Remove the synchronizer ring from the counter 5th gear.

  37. REMOVE COUNTER SHAFT 5TH GEAR


    1. A00XICOE01

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

  38. REMOVE COUNTER 5TH GEAR BEARING


    1. A00XIQFE01

      Remove the bearing from the counter 5th gear.

  39. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. A00XFCJ

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

    2. A00XGMZE01
      Text in Illustration
      *1 No. 3 Synchromesh Shifting Key Spring
      *2 No. 3 Synchromesh Shifting Key
      *3 Counter 5th Gear

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

  40. REMOVE 5TH GEAR THRUST WASHER


    1. A00XHNHE01

      Remove the thrust washer from the counter gear.

  41. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A00XEMCE01

      Remove the thrust washer pin from the counter gear.

  42. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A00XDBUE01

      Remove the 4 bolts and bearing retainer from the intermediate plate.

  43. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00XF70E01

      Pull out the reverse idler gear shaft from the rear side and remove the reverse idler gear from the intermediate plate.

  44. REMOVE COUNTER SHAFT CENTER BEARING


    1. A00XEE1E01

      Using a snap ring expander, remove the snap ring from the center bearing.

    2. A00XCZTE01

      Using SST, remove the center bearing from the intermediate plate.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 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.

  45. REMOVE COUNTER GEAR


    1. A00XF5XE01

      Remove the counter gear from the intermediate plate.

  46. REMOVE INPUT SHAFT


    1. A00XGRGE01

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

      Note

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

  47. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING (for Center Bearing Side)


    1. A00XKC8E01

      Using a snap ring expander, remove the snap ring from the center bearing.

  48. REMOVE OUTPUT SHAFT


    1. A00XC5KE01

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