Manual Transmission Unit Disassembly

Loosen the hose clamp, and remove the breather hose.

Remove the wire harness clamp.

Loosen the hose clamp, and remove the breather hose.

Remove the 10 bolts and clutch housing.

Remove the filler plug.

Remove the gasket from the filler plug.

Remove the drain plug.

Remove the gasket from the drain plug.

Using a T55 "TORX" socket wrench, remove the transmission case plug.

Remove the gasket from the transmission case plug.

Disconnect the wire harness clamp.

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

SST

09817-16011

Disconnect the wire harness clamp.

Using SST, remove the shift position switch and gasket.

SST

09817-16011

Remove the 6 bolts and control shaft cover.

Remove the 2 restrict pins.

Remove the 4 bolts.

Using a plastic-faced hammer, remove the floor shift control shift lever retainer.

Remove the slotted pin.

Remove the No. 1 reverse restrict pin and spring.

Remove the 5 bolts and oil pump cover.

Using a magnet hand, remove the 2 pins.

Remove the oil pump cover O-ring from the oil pump cover.

Using a screwdriver, pry out the oil pump cover oil seal.

NOTICE:

Be careful not to damage the oil seal and oil pump cover contact surfaces.

HINT:

Tape the screwdriver tip before use.

Remove the 8 bolts and front bearing retainer.

Using a screwdriver, pry out the oil seal.

NOTICE:

Be careful not to damage the oil seal and front bearing retainer contact surfaces.

HINT:

Tape the screwdriver tip before use.

Using a 14 mm hexagon wrench, remove the interlock hole plug.

Remove the 3 bolts, shift and select lever shaft, shift and select lever and shift lever housing.

Remove the 11 bolts and transfer adapter.

Remove the 4 straight pins from the transfer adapter.

Remove the 2 ring pins from the transfer adapter.

Using a T40 "TORX" socket wrench, remove the transfer adapter plug.

Remove the 2 bolts and oil strainer.

Remove the O-ring from the oil strainer.

Remove the transmission magnet.

Remove the thrust washer.

Remove the reverse idler gear.

Remove the bearing.

Remove the thrust washer.

Remove the reverse idler gear shaft.

Remove the woodruff key from the reverse idler gear shaft.

Using a snap ring expander, remove the 2 snap rings from the input shaft and counter gear.

Using a brass bar and hammer, carefully tap the transmission case.

Remove the transmission case from the intermediate plate.

Remove the 2 bolts and oil receiver pipe from the transmission case.

Remove the 4 straight pins from the transmission case.

Remove the 4 straight pins from the intermediate plate.

Remove the 3 bolts and oil receiver from the intermediate plate.

Using a T40 "TORX" socket wrench, remove the 4 ball plugs.

Using a magnet hand, remove the 4 springs and 4 balls.

Using 2 screwdrivers and a hammer, tap out the 4 snap rings.

HINT:

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

Remove the No. 4 gear shift fork set bolt.

Remove the No. 4 gear shift fork shaft and 2 balls.

Remove the reverse shift fork.

Using a magnet hand, remove the ball.

Remove the No. 3 gear shift fork set bolt.

Remove the No. 3 shift gear fork shaft and reverse shift head.

Using a magnet hand, remove the interlock pin from the No. 3 gear shift fork shaft.

Remove the No. 3 gear shift fork.

Using a magnet hand, remove the interlock pin.

Remove the No. 1 gear shift fork set bolt.

Remove the No. 1 gear shift fork shaft.

Using a magnet hand, remove the interlock pin from the No. 1 gear shift fork shaft.

Remove the No. 1 gear shift fork.

Using a magnet hand, remove the interlock pin.

Remove the No. 2 gear shift fork set bolt.

Remove the No. 2 gear shift fork shaft.

Remove the No. 2 gear shift fork.

Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT:

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

Using SST, remove the No. 4 transmission clutch hub.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03080)

Remove the reverse synchronizer ring set and reverse gear.

Remove the reverse synchronizer ring set from the reverse gear.

Remove the reverse gear bearing.

Remove the No. 1 transmission hub sleeve, 3 shifting keys, and 3 springs from the No. 4 transmission clutch hub.

HINT:

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

Remove the 4 bolts and rear bearing retainer.

Using a snap ring expander, remove the snap ring.

Using SST, remove the outer race.

SST

09950-40011(09951-04020,09952-04010,09953-04030,09954-04020,09955-04011,09957-04010,09958-04011)

NOTICE:

Do not drop the counter gear. Hold the front side of the counter gear when removing the bearing outer race.

Using a screwdriver, remove the center bearing and counter gear.

Remove the input shaft from the output shaft.

NOTICE:

Do not drop the input shaft bearing.

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

Using a snap ring expander, remove the snap ring.

Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.