Manual Transmission Unit (For 1Kd-Ftv) Disassembly

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

Remove the clip and release bearing from the release fork.

Remove the clutch release fork support boot from the front transmission case.

Remove the release fork support from the manual transmission unit.

Remove the 4 bolts.

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

Remove the bolt and shift lever housing.

Remove the 4 bolts and manual transmission case cover.

Using a 10 mm hexagon socket wrench, remove the shift detent ball plug from the transfer adapter.

Remove the ball and compression spring from the transfer adapter.

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

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

Engage 5th gear, and then secure the input shaft using SST.

SST

09322-35010(09322-03010,09322-03020,09322-03030,90105-12087,90170-12030)

HINT:

1. Install SST securely so that the part labeled A is in-line with the input shaft.
   
2. Make sure that the part labeled A moves back and forth by hand after installing SST.
   

Using an L-type handle and SST, remove the manual transmission output shaft rear set nut from the output shaft.

SST

09326-35010(09326-03010)

Remove the belt and wooden block from the manual transmission.

Remove the rear output shaft bearing (inner race) and output shaft spacer.

Remove the 10 bolts and 2 brackets.

Using a plastic-faced hammer, carefully tap off the transfer adapter to remove it.

HINT:

Place a brass bar against the rib portion of the transfer adapter.

Remove the 2 manual transmission filler plugs and 2 gaskets from the transfer adapter.

Remove the No. 1 oil receiver pipe from the transfer adapter.

Remove the oil separator packing seal from the transfer adapter.

Using a 14 mm hexagon socket wrench, remove the transfer adapter case plug from the transfer adapter.

Using SST, remove the 2 rear output shaft bearings (outer race) from the transfer adapter.

SST

09308-00010

Remove the bolt and bearing lock plate.

Using SST, remove the counter gear rear radial ball bearing from the transfer adapter.

SST

09308-00010

Remove the transfer adapter needle roller bearing from the transfer adapter.

Remove the 2 bolts and transmission oil separator.

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

Remove the 11 bolts.

Using a plastic-faced hammer, carefully tap off the transmission middle case to remove it.

HINT:

Place a brass bar against the rib portion of the transmission middle case.

Remove the drain plug sub-assembly and gasket from the transmission middle case.

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

Remove the shift and select lever shaft from the reverse gear shaft.

Using a screwdriver, remove the E-ring.

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

Remove the bolt, shift and select lever, shift and select cam and shift interlock plate from the lever shaft.

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

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

SST

09817-16011

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.13 to 0.154 mm (0.00512 to 0.00606 in.)

Maximum clearance:

0.154 mm (0.00606 in.)

1. If the clearance is more than the maximum, replace the reverse idler gear shaft, reverse idler gear or front transmission case.
   

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

Remove the 4 bolts from the shift interlock bracket.

Using a 27 mm hexagon wrench, remove the manual transmission case plug.

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

Expand the 2 front bearing shaft snap rings and lift up the output shaft assembly, input shaft assembly, counter gear assembly, shift interlock bracket, gear shift forks and gear shift fork shafts.

Remove the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks and gear shift fork shafts while gently tapping the clutch housing with a plastic-faced hammer.

NOTICE:

Take care not to subject the output shaft assembly, input shaft assembly, counter gear assembly, shift interlock bracket, gear shift forks and gear shift fork shafts to any impact. This could cause the ball and spring to come out.

Separate the output shaft assembly, input shaft assembly, counter gear assembly and gear shift forks.

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

Using snap ring pliers, remove the 2 front bearing shaft snap rings.

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

SST

09308-00010

Using SST, remove the transmission case needle bearing from the front transmission case.

SST

09319-60020

Text in Illustration

*1	Transmission Case Needle Bearing	-	-
*a	Hold	-	-
	Turn	-	-

Remove the bolt and No. 3 gear shift fork.

Remove the No. 3 gear shift fork shaft, shift detent ball and compression spring.

Remove the bolt and No. 2 gear shift fork.

Remove the No. 2 gear shift fork shaft, shift detent ball and compression spring.

Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the No. 1 gear shift head.

Remove the No. 1 gear shift fork shaft, shift detent ball, compression spring and No. 1 gear shift head.

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

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

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

Remove the No. 4 gear shift fork.

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

Using a screwdriver, remove the E-ring.

Remove the shift arm pivot and No. 1 release arm.