Manual Transmission Unit Disassembly

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

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

Remove the release fork and release bearing from the clutch housing.

Remove the clip and release bearing from the release fork.

Remove the release fork support from the clutch housing.

Remove the clutch release fork boot from the clutch housing.

Remove the 9 bolts.

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

Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

SST

09817-16011

Remove the 2 restrict pins from the transfer adapter.

Remove the 4 bolts and floor shift control shift lever retainer sub-assembly.

Remove the gasket.

Remove the 10 bolts.

Using a brass bar and hammer, tap off the transfer adapter from the manual transmission case.

Remove the transfer oil receiver pipe from the transfer adapter.

Remove the bolt from the shift lever housing.

Remove the shift and select lever and shift lever housing from the transfer adapter.

Using a T40 "TORX" socket wrench, remove the reverse restrict pin plug.

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

Remove the reverse restrict pin assembly.

Using a screwdriver and hammer, tap out the transfer adapter oil seal from the transfer adapter.

Remove the 8 bolts.

Using a brass bar and hammer, tap off the front bearing retainer from the manual transmission case.

Secure the front bearing retainer in a vise between aluminum plates.

Using SST, tap out the transmission front bearing retainer oil seal.

SST

09308-00010

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

Using a snap ring expander, remove the front No. 1 counter bearing snap ring from the front counter gear bearing.

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

Remove the transmission magnet from the intermediate plate.

Secure the intermediate plate in a vise between aluminum plates.

for Type A:
Using a 6 mm hexagon socket wrench, remove the No. 1 shift detent ball spring seat from the intermediate plate.

for Type B:
Using a T40 "TORX" socket wrench, remove the No. 1 shift detent ball spring seat from the intermediate plate.

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

for Type A:
Using a 6 mm hexagon socket wrench, remove the 2 No. 1 shift detent ball spring seats from the intermediate plate.

for Type B:
Using a T40 "TORX" socket wrench, remove the 2 No. 1 shift detent ball spring seats from the intermediate plate.

Using a magnet hand, remove the 2 compression springs and 2 detent balls from the intermediate plate.

Using 2 screwdrivers and a hammer, tap off the snap ring from the No. 2 gear shift fork shaft.

NOTICE:

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

Remove the bolt from the No. 2 shift fork.

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

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

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

Using 2 screwdrivers and a hammer, tap off the snap ring from the No. 1 gear shift fork shaft.

NOTICE:

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

Remove the bolt from the No. 1 shift fork.

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

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

Using a 5 mm pin punch and hammer, tap out the shift fork set slotted spring pin from the No. 3 shift fork.

Using 2 screwdrivers and a hammer, tap off the snap ring from the No. 3 gear shift fork shaft.

NOTICE:

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

Using a magnet hand, remove the straight pin from the reverse shift fork.

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

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

Remove the reverse shift fork from the reverse shift arm.

Remove the torsion spring from the reverse shift arm bracket.

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

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

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

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

NOTICE:

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

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)
09950-60010(09951-00300)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.00394 to 0.0137 in.)

1. If the clearance is not as specified, replace the counter 5th gear.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000591 to 0.00267 in.)

1. If the clearance is not as specified, replace the counter 5th gear bearing with a new one.
   

Using 2 screwdrivers and a hammer, tap off the counter gear rear shaft snap ring from the counter gear.

NOTICE:

Use a piece of cloth to prevent the counter gear rear shaft snap ring from flying off.

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

Using SST, remove the counter 5th gear together with the counter 5th gear bearing, 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 5th gear.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021,09957-04010)

Remove the No. 5 gear spline piece from the counter 5th gear.

Remove the outer No. 3 synchronizer ring from the counter 5th gear.

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

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

Remove the No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring from the counter 5th gear.

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

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

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

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

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

Using SST, remove the counter shaft center bearing from the intermediate plate.

SST

09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04011,09957-04010,09958-04011)
09950-60010(09951-00260)

NOTICE:

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

Remove the counter gear from the intermediate plate.

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

NOTICE:

Do not drop the input shaft bearing or No. 2 synchronizer ring.

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

Using a plastic-faced hammer, remove the output shaft by tapping the intermediate plate.