Manual Transmission Unit Disassembly

Remove the bolt and separate the wire harness clamp.

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

SST

09817-16011

Remove the floor shift control shift lever retainer sub-assembly.

Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.

Remove the floor shift control shift lever retainer.

Remove the shift and select lever boot.

Remove the 4 shift lever retainer bushings.

Using a screwdriver, remove the E-ring and control shaft.

Remove the 2 collars from the floor shift control shaft.

Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shaft.

Remove the shaft pin and floor shift control shaft.

Remove the shift lever damper from the floor shift control shaft.

Using a plastic hammer, remove the extension housing dust deflector.

Remove the 8 bolts.

Using a plastic hammer, carefully tap out the extension housing.

Remove the extension housing.

Using SST, remove the extension housing rear oil seal.

SST

09612-70100(09612-07210)

Using SST, remove the extension housing oil seal.

SST

09308-00010

Using a snap ring expander, remove the snap ring.

Remove the oil receiver pipe.

Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case.

Remove the ball and compression spring from the transmission rear case.

Using a belt and wooden block, fasten the transmission to the workbench.

Using a chisel and hammer, unstake the nut.

Place the gearshift into 5th gear, and then fix the input shaft using SST.

SST

09556-16030

Using SST, remove the nut from the output shaft.

SST

09922-10010

Remove the belt and wooden block from the transmission.

Remove the No. 2 taper roller bearing and spacer.

Remove the 10 bolts and bracket.

Using a plastic hammer, carefully tap out the rear case.

Remove the rear case.

Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.

Remove the extension housing oil receiver pipe from the transmission rear case.

Remove the oil separator packing seal from the transmission rear case.

Using SST, remove the 2 bearing outer races.

SST

09308-00010

Remove the bolt, then remove the bearing lock plate.

Using SST, remove the counter gear rear cylindrical roller bearing from the transmission rear case.

SST

09308-00010

Using SST and a press, remove the transmission rear case bearing from the transmission rear case.

SST

09950-60010(09951-00230)

Remove the 2 bolts, then remove the oil separator.

Remove the reverse idler gear shaft bolt and gasket from the transmission middle case.

Remove the 11 bolts, then remove the transmission middle case.

Using a plastic hammer, carefully tap out the transmission middle case.

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

Remove the No. 2 oil receiver pipe from the transmission middle case.

Using SST and a press, remove the transmission middle case bearing from the transmission middle case.

SST

09950-60010(09951-00230)

Remove the shift and select lever shaft.

Remove the bolt, then remove the shift and select lever.

Remove the lock ball pin and spring from the shift and select lever.

Using a screwdriver, remove the E-ring and the shift and select lever cam from the shift and select lever shaft.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Maximum clearance:

0.25 (0.0098 in.)

Remove the reverse idle gear shaft, reverse idler gear bearing and reverse idler gear.

Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.050 mm (0.0006 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

Using a hexagon wrench (24 mm), remove the plug from the transmission front case.

Remove the 4 bolts from the shift interlock bracket.

Tie the input shaft, counter gear and control assembly with a rope or string.

Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.

Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the front case with a plastic hammer.

NOTICE:

Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This may cause the ball and spring to come out.

Separate the output shaft, input shaft, counter gear shaft and control assembly.

Remove the No. 1 oil receiver pipe from the transmission front case.

Using snap ring pliers, remove the 2 snap rings.

Using SST, remove the transmission case oil seal from the transmission front case.

SST

09308-00010

Using 2 screwdrivers, remove the 4 snap rings.

Remove the bolt, then remove the No. 3 gear shift fork.

Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.

Remove the bolt, then remove the No. 2 gear shift fork.

Remove the No. 2 gear shift fork shaft, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.

Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

Remove the No. 3 gear shift fork shaft, ball, spring, No. 3 gear shift head and No. 1 shift interlock pin.

Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

Remove the No. 2 gear shift head and No. 1 gear shift fork.

Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

Remove the No. 4 gear shift fork.

Remove the No. 4 gear shift fork shaft, ball and spring.

Using a screwdriver, remove the E-ring.

Remove the shift arm pivot and shift arm.