БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ РАЗБОРКА

PROCEDURE


  1. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  2. REMOVE RELEASE FORK SUPPORT

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  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  4. REMOVE BACK-UP LIGHT SWITCH BRACKET


    1. B003KTD

      Remove the 3 bolts and 3 back-up light switch brackets.

  5. REMOVE TRANSMISSION REVOLUTION SENSOR (w/ Intelligent Manual Transmission Switch)

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  6. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. B003SCMC01
      *1 Manual Transmission Filler Plug
      *2 Drain Plug Sub-assembly
      *3 Manual Transmission Case Plug

      Remove the manual transmission filler plug, drain plug sub-assembly and 2 gaskets from the manual transmission case sub-assembly.

    2. Using a 10 mm hexagon wrench, remove the manual transmission case plug and gasket from the manual transmission case sub-assembly.

  7. REMOVE SHAFT DETENT BALL


    1. B003O0W

      Using a 6 mm hexagon wrench, remove the 4 shaft detent ball plugs from the rear transmission case.

    2. Remove the 4 shaft detent ball compression springs and 4 shaft detent balls from the rear transmission case.

  8. REMOVE LOCK BALL PIN


    1. B003L8Z

      Using a 10 mm hexagon wrench, remove the No. 2 with head straight screw plug from the rear transmission case.

    2. Remove the shift and select lever spring and the lock ball pin from the rear transmission case.

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


    1. B003QLT

      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.

  10. REMOVE SHIFT LEVER HOUSING


    1. B003NVD

      Remove the bolt and shift lever housing.

      Note

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

  11. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. B003QWK

      Remove the 8 bolts and extension housing sub-assembly.

  12. REMOVE NO. 4 OIL RECEIVER PIPE


    1. B003LIH

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

  13. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

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  14. REMOVE TRANSMISSION OIL SEPARATOR


    1. B003JO1

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

  15. REMOVE TRANSMISSION OIL RUNNER


    1. B003RT7

      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.

  16. UNSTAKE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B003LIL

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

  17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. B003R1ZC02
      *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. B003J6YN01

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

      SST
      09326-35020

  18. REMOVE CLUTCH HOUSING


    1. B003O6R

      Remove the 10 bolts.

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

  19. REMOVE FRONT BEARING RETAINER


    1. B003O1H

      Remove the 11 bolts.

    2. B003R77

      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.

  20. REMOVE NO. 1 OIL RECEIVER PIPE


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

  21. REMOVE FRONT TRANSMISSION BEARING RETAINER OIL SEAL

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  22. REMOVE COUNTER GEAR SHAFT NUT


    1. B003QW1

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

    2. B003M6SN01

      Using SST, hold the output shaft.

      SST
      09326-35020

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

  23. REMOVE INPUT SHAFT SHAFT SNAP RING


    1. B003L21

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

  24. REMOVE FRONT BEARING SHAFT SNAP RING


    1. B003MEY

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

  25. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. B003JZK

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

  26. 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. B003RE5

      Remove the 12 bolts.

    2. B003P7Q

      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. B003OSGC01
      *1 Straight Pin
      *a Protective Tape

      Using a screwdriver wrapped in protective tape, separate the transmission case sub-assembly and transmission 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. B003RAF

      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.

  27. 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 manual transmission in place.


    1. B003JH4

      Remove the reverse idler gear and No. 2 oil receiver pipe from the transmission unit.

    2. Remove the No. 2 oil receiver pipe from the reverse idler gear shaft.

    3. B003QWW

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

  28. REMOVE SHIFT AND SELECT LEVER SHAFT


    1. B003MU0

      Remove the shift and select lever shaft 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 lever shaft, have the other person hold the manual transmission in place.

  29. REMOVE SHIFT INTERLOCK PLATE STOPPER


    1. B003M81

      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 manual transmission in place.

  30. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. B003M2N

      Remove the 2 bolts and manual 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 manual transmission in place.

  31. REMOVE TRANSMISSION MAGNET


    1. B003J2U

      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 transmission magnet, have the other person hold the manual transmission in place.

  32. REMOVE REAR TRANSMISSION CASE


    1. B003KYFN01

      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. B003MW1N01

      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. B003RVL

      Remove the rear output shaft bearing.

    4. B003K4J

      Remove the rear transmission case and transmission intermediate plate.

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

    6. B003JEF

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

  33. REMOVE NO. 3 OIL RECEIVER PIPE


    1. B003J6T

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

  34. REMOVE SHIFT FORK AND SHIFT FORK SHAFT ASSEMBLY


    1. B003PXYC02
      B003OFB 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. B003NJ4C03
      B003OFB 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. B003PHLC02
      *1 No. 2 Transmission Hub Sleeve
      *2 No. 1 Transmission Hub Sleeve
      *3 No. 4 Gear Shift Fork Shaft
      B003OFB Remove in this direction

      Slide the No. 2 and No. 1 transmission 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. B003KZAC02
      B003OFB 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. B003OSU

      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. B003SG0

      Remove the No. 4 gear shift fork.

  35. REMOVE OUTPUT SHAFT


    1. B003SAWC01
      *1 Input Shaft
      *2 Counter Gear

      Expand SST to the left and right.

    2. B003OWK

      Remove the output shaft from the transmission unit.

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

  36. REMOVE INPUT SHAFT BEARING


    1. B003M9B

      Remove the input shaft bearing from the input shaft.

  37. REMOVE NO. 4 SYNCHRONIZER RING


    1. B003P6O

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

  38. REMOVE INPUT SHAFT


    1. Remove the input shaft from SST.

  39. REMOVE COUNTER GEAR


    1. Remove the counter gear from SST.

  40. REMOVE REAR COUNTER GEAR BEARING OR ROLLER


    1. B003MAN

      Remove the bolt and bearing lock plate.

    2. B003K6ZC01
      *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.

  41. REMOVE FRONT OUTPUT SHAFT BEARING

    Click here

  42. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)


    1. B003JPNC01
      *a Groove of the Rear Transmission Case

      Using SST, remove the rear 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 FRONT OUTPUT SHAFT BEARING (OUTER RACE)


    1. B003M0VC01
      *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.

  44. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. B003JKAC01
      *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. B003OC4C02
      *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. B003O6CC01
      *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. B003L4JC02
      *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. B003OGN

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

    2. B003KTZ

      Remove the bolt from the inner select lever.

    3. B003Q7I

      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. B003MRZ

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

    6. B003KQQ

      Using 2 screwdrivers and a hammer, tap off the shift arm pivot 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. B003LJWC01
      *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. B003L2T

      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. B003QL3

      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. B003M2E

      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.

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

    3. Remove the No. 4 gear shift head from the No. 4 gear shift fork shaft.

  52. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. B003KMG

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

    2. B003OZO

      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. B003M15

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

  54. REMOVE STRAIGHT PIN AND RING PIN

    Note

    It is not necessary to remove the straight pin and ring pin unless it is being replaced.