Manual Transmission Disassembly

Manual Transmission Disassembly

Exploded View - Clutch Housing





Exploded View - Clutch Housing Exploded View - Transmission Housing





NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Remove the air cleaner housing bracket (A) and the harness bracket (B).






2. Remove the detent bolts (A), the 12 mm washers (B), the springs (C), and the steel balls (D).

3. Remove the 20 mm bolt (E) and the 20 mm washer (F).






4. Remove the change lever assembly (A) and the 8 x 10 mm dowel pins (B).






5. Remove the transmission hanger (A), the back-up light switch (B), and the 18 mm washer (C).






6. Remove the drain plug (A), the filler plug (B), the sealing washers (C), and the output shaft (countershaft) speed sensor (D) with the O-ring (E).






7. Remove the 8 mm flange bolts in a crisscross pattern in several steps.






8. Remove the 32 mm sealing cap (A).

9. While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C). Release the snap ring pliers, and remove the transmission housing and the two 14 x 20 mm dowel pins (D).






10. Remove the reverse shift fork (A).






11. Remove the reverse idler gear (A) and the reverse idler gear shaft (B).






12. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

13. Remove the 36 mm spring washer (E) and the 26 mm washer (F).






14. Remove the differential assembly (A) and the magnet (B).






15. Remove the oil gutter plate (A), the 52 x 62 mm shim (B), and oil guide plate M.