MANUAL TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01SDG0

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

  2. REMOVE DRAIN PLUG SUB-ASSEMBLY


    1. A01SC9X

      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. A01SDVGC03
      *A for 2TR-FE
      *B for 5L-E

      Remove the 9 bolts.

    2. A01SCOA

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  8. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01SESMC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

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

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


    1. A01SAYCC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

      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. A01SDPC

      Remove the 10 bolts and 2 wire harness brackets.

    2. A01SA7Q

      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. A01SEFHC01
      *A w/ Console Box Lid
      *B w/o Console Box Lid

      Remove the bolt from the shift lever housing.

    2. A01SCOIC01
      *A w/ Console Box Lid
      *B w/o Console Box Lid

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

  12. REMOVE TRANSFER OIL RECEIVER PIPE


    1. A01SAEI

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

  13. REMOVE REVERSE RESTRICT PIN


    1. A01SEOF

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

    2. A01SEZX

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

    3. A01SALD

      Remove the reverse restrict pin.

  14. REMOVE TRANSFER ADAPTER OIL SEAL

    Click here

  15. REMOVE FRONT BEARING RETAINER


    1. A01SDN9

      Remove the 8 bolts.

    2. A01SBDZ

      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. A01SE9C

      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. A01SDHQ

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A01SD3I

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

  20. REMOVE TRANSMISSION MAGNET


    1. A01SALF

      Remove the transmission magnet from the intermediate plate.

  21. SECURE INTERMEDIATE PLATE


    1. A01SD7V

      Secure the intermediate plate in a vise between aluminum plates.

  22. REMOVE SHIFT DETENT BALL PLUG


    1. A01SBXDC03
      *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. A01SCEB

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

    3. A01SE0TC02
      *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. A01SBPH

      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. A01SDW8

      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. A01SDAH

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

    3. A01SAAW

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

    4. A01SBFZ

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

    5. A01SAQS

      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. A01SDUH

      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. A01SB7P

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

    3. A01SBHK

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

    4. A01SBO3

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

    5. A01SETF

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

  25. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01SDY2

      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. A01SDQR

      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. A01SE18

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

    4. A01SBR2

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

  26. REMOVE REVERSE SHIFT FORK


    1. A01SC8S

      Remove the reverse shift fork from the reverse shift arm.

  27. REMOVE REVERSE SHIFT ARM BRACKET


    1. A01SAUI

      Remove the torsion spring from the reverse shift arm bracket.

    2. A01SE82

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

    3. A01SETY

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

    4. A01SDW3

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

  28. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01SDOE

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

    2. A01SDUPC01
      *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. A01SE91

      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. A01SB0T

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

  33. REMOVE COUNTERSHAFT 5TH GEAR


    1. A01SDZTN01

      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. A01SADCC02
      *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. A01SCN1

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

  37. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. A01SDWV

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

    2. A01SE7DC02
      *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. A01SE4H

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

  39. REMOVE 5TH GEAR THRUST WASHER PIN


    1. A01SDSA

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

  40. REMOVE OUTPUT SHAFT REAR BEARING RETAINER


    1. A01SB0Y

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

  41. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01SE5X

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

  42. REMOVE COUNTER SHAFT REAR BEARING


    1. A01SBI2

      Using a snap ring expander, remove the snap ring.

    2. A01SE7AN03

      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. A01SBNB

      Remove the counter gear from the intermediate plate.

  44. REMOVE INPUT SHAFT


    1. A01SB8H

      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. A01SDRZ

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

  47. REMOVE OUTPUT SHAFT


    1. A01SCTJ

      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

    Click here