REMOVE MANUAL TRANSMISSION FILLER PLUG
Remove the filler plug and gasket from the manual transmission case.
REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY
Using a 10 mm hexagon socket wrench, remove the drain plug and gasket from the manual transmission case.
REMOVE SPEEDOMETER SENSOR
Remove the bolt and speedometer sensor.
Using a screwdriver, remove the O-ring from the speedometer sensor.
REMOVE BACK UP LIGHT SWITCH ASSEMBLY
Using SST, remove the back up light switch assembly and gasket from the manual transmission case.
REMOVE CLUTCH HOUSING
Remove the 9 bolts.
Using a plastic hammer, remove the clutch housing from the transmission case.
REMOVE SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY
Remove the 6 bolts, shift lever shaft housing and clamp from the manual transmission case.
Remove the shift lever shaft housing gasket from the manual transmission case.
REMOVE EXTENSION HOUSING DUST(MTM) DEFLECTOR
Using a brass bar and a hammer, remove the extension housing dust deflector from the extension housing.
REMOVE EXTENSION (MTM) HOUSING SUB-ASSEMBLY
Remove 8 bolts.
Using a plastic hammer, remove the extension housing from the manual transmission case.
REMOVE TRANSMISSION MAGNET
Remove the transmission magnet from the extension housing.
REMOVE EXTENSION HOUSING OIL RECEIVER PIPE
Remove the bolt and extension housing oil receiver pipe from the extension housing.
REMOVE EXTENSION HOUSING OIL RECEIVER PIPE NO.1
Remove the extension housing oil receiver pipe No.1 from the extension housing.
REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL
Using SST, remove the manual transmission extension housing oil seal from the extension housing.
REMOVE BEARING RETAINER FRONT(MTM)
Remove the 8 bolts.
w/o Gasket:
Remove the bearing retainer from the transmission case.
w/ Gasket:
Remove the bearing retainer front and transmission front bearing retainer gasket from the manual transmission case.
REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL
Using a screwdriver, remove the transmission front bearing retainer oil seal from the bearing retainer front.
REMOVE FRONT BEARING SHAFT SNAP RING
Using a snap ring expander, remove the front bearing shaft snap ring from the manual transmission case.
REMOVE COUNTER GEAR FRONT BEARING SNAP RING NO.1
Using a snap ring expander, remove the counter gear front bearing snap ring No.1 from the manual transmission case.
REMOVE MANUAL TRANSMISSION CASE
Stand the manual transmission assembly as shown in the illustration.
Using a plastic hammer, carefully tap off the manual transmission case.
Remove the manual transmission case from the intermediate plate as shown in the illustration.
FIX INTERMEDIATE PLATE
Fix the intermediate plate in a vise.
REMOVE SHIFT DETENT BALL
Using a "torx" socket wrench T40, remove the 3 shift detent ball spring seats No.1 from the intermediate plate.
Using a magnetic finger, remove the 3 compression springs and 3 shift detent balls from the intermediate plate.
REMOVE SHIFT DETENT BALL NO.2
Using a "torx" socket wrench T40, remove the shift detent ball spring seat No.2 from the intermediate plate.
Using a magnetic finger, remove the compression spring and shift detent ball No.2 from the intermediate plate.
REMOVE GEAR SHIFT FORK SHAFT NO.4
Remove the shift fork bolt from the gear shift fork No.3.
Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the reverse shift head.
Using 2 screwdrivers and a hammer, remove the shaft snap ring from the gear shift fork shaft No.4
Note
Use a shop rag to prevent the snap ring from flying off.
Remove the ball from the intermediate plate.
Remove the gear shift fork shaft No.4 and reverse shift fork ball.
REMOVE REVERSE SHIFT HEAD
Remove the reverse shift head from the reverse shift fork shaft.
REMOVE GEAR SHIFT HEAD NO.3
Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the gear shift head No.3.
Remove the gear shift head from the reverse shift fork shaft.
REMOVE SHIFT INTER LOCK PIN NO.2
Using a magnetic finger, remove shift inter lock pin No.2 from the reverse shift fork shaft.
REMOVE REVERSE SHIFT FORK SHAFT
Remove the reverse shift fork shaft, ball and compression spring.
Note
Cover the hole with a shop rag to prevent the ball from popping out.
REMOVE SHIFT INTER LOCK PIN NO.1
Using a magnetic finger, remove the shift inter lock pin No.1 from the intermediate plate.
REMOVE SHIFT INTER LOCK PIN NO.2
Using a magnetic finger, remove shift inter lock pin No.2 from the gear shift fork shaft No.2.
REMOVE GEAR SHIFT FORK SHAFT NO.2
Using a pin punch and a hammer, remove the slotted spring pin from the gear shift fork No.2.
Remove the shift fork shaft snap ring from the gear shift fork shaft No.2.
Remove the gear shift fork shaft No.2 from the intermediate plate.
REMOVE SHIFT INTER LOCK PIN NO.1
Using a magnetic finger, remove shift inter lock pin No.1 from the intermediate plate.
REMOVE GEAR SHIFT FORK SHAFT NO.1
Remove the shift fork bolt from the gear shift fork No.1.
Remove the gear shift fork shaft No.1 assembly and gear shift fork No.1 from the intermediate plate.
Using a pin punch (5 mm) and a hammer, remove the slotted spring pin from the gear shift head No.1.
Remove the gear shift head No.1 from the gear shift fork shaft No.1.
REMOVE GEAR SHIFT FORK NO.2
Remove the gear shift fork No.2 from the transmission hub sleeve No.2.
INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.
Standard clearance |
---|
0.125 to 0.325 mm (0.0049 to 0.0128 in.) |
Maximum clearance |
---|
0.325 mm (0.0128 in.) |
REMOVE COUNTER SHAFT 5TH GEAR
Using 2 screwdrivers and a hammer, tap out the counter gear rear shaft snap ring from the counter gear.
Using SST, remove the gear spline piece No.5 and synchronizer ring No.3 from the counter gear.
Remove the counter shaft 5th gear assembly and counter 5th gear bearing from the counter gear.
REMOVE 5TH GEAR THRUST WASHER
Remove the 5th gear thrust washer from the counter gear.
Using a magnetic finger, remove the 5th gear bearing inner race lock ball from the counter gear.
REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket with the shift arm from the intermediate plate.
REMOVE REVERSE SHIFT ARM
Using a screwdriver, remove the E-ring.
Remove the shift fork from the shift arm.
REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
Remove the bolt and reverse idler gear shaft stopper from the intermediate plate.
Remove the the reverse idler gear shaft and reverse idler gear sub-assembly from the intermediate plate.
INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
Using a dial indicator, inspect the reverse idler gear radial clearance.
Standard clearance |
---|
0.04 to 0.08 mm (0.0016 to 0.0031 in.) |
Maximum clearance |
---|
0.13 mm (0.0051 in.) |
If the clearance exceeds the maximum, replace the reverse idler gear.
INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
Using a feeler gauge, measure the clearance between the reverse idler gear and reverse shift arm.
Standard clearance |
---|
0.05 to 0.35 mm (0.0020 to 0.0138 in.) |
Maximum clearance |
---|
0.35 mm (0.0138 in.) |
If the clearance exceeds the maximum, replace the reverse idler gear and reverse shift arm.
REMOVE OUTPUT SHAFT REAR BEARING(MTM) RETAINER
Using a "torx" socket wrench T40, remove the 4 screws and output shaft rear bearing retainer from the intermediate plate.
REMOVE COUNTER GEAR
Using a snap ring expander, remove the snap ring from the counter shaft center bearing.
Using SST, remove the counter shaft center bearing and the counter gear assembly from the intermediate plate.
REMOVE INPUT SHAFT ASSEMBLY
Remove the input shaft assembly with the 13 input shaft bearings and synchronizer ring No.1 from the output shaft.
REMOVE OUTPUT SHAFT ASSEMBLY
Using a snap ring expander, remove the output shaft bearing snap ring from the output shaft assembly.
Remove the output shaft assembly from the intermediate plate by pulling on the output shaft assembly and tapping on the intermediate plate with a plastic hammer.