Manual Transmission Disassembly
Manual Transmission Disassembly
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 release bearing and the release fork Service and Repair.
2. Remove the strainer cover (A), the O-ring (B), the strainer set spring (C), and the oil pump strainer (D).
3. Remove the reverse lockout solenoid (A), the select lock pin (B), the select lock pin spring (C), and the back-up light switch (D).
4. Remove the detent bolts (A), the 22.0 mm detent ball spring (B), the 26.1 mm detent ball spring (C), the 27.4 mm detent ball springs (D), the steel balls (E), the filler plug (F), and the 20 mm sealing washer (G).
5. Remove the detent bolts (A), the 22.0 mm detent ball spring (B), the 27.4 mm detent ball spring (C), the steel balls (D), the input shaft (mainshaft) speed sensor (E), the output shaft (countershaft) speed sensor (F), and the O-rings (G).
6. Remove the oil check bolt (A), the 6 mm sealing washer (B), the drain plug (C), and the 14 mm sealing washer (D).
7. Remove transmission hanger A, transmission hanger B, and the clutch line bracket (C). Loosen the 10 mm flange bolts in a crisscross pattern in several steps, then remove them.
8. Remove the transmission case cap (A) and the O-ring (B).
9. Expand the 75 mm snap ring (C) on the countershaft ball bearing, and remove it from the groove using snap ring pliers.
10. Remove the transmission housing (D) and the three 14 x 20 mm dowel pins (E).
11. Remove oil guide pipe A, oil guide pipe B, and the magnet (C).
12. Remove the 8 x 50 mm pin (A) and the reverse shift lever (B).
13. Remove the 20 mm thrust washers (A), the 20 mm thrust needle bearings (B), the reverse idler gear shaft assembly (C), the 33 mm spring washer (D), and the reverse shift fork (E) as an assembly.
14. Remove the 8 x 50 mm pin (A), the select return spring (B), the shift piece shaft (C), the shift piece (D), and the interlock (E).
15. Remove the 5 x 22 mm, 3 x 22 mm spring pins (A), the select arm (B), the 14 x 20 x 4 mm dust seal (C), and the select lever (D).
16. 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).
17. Remove the 64 mm spring washer (E).
18. Remove the oil pump shaft (A) and the differential assembly (B).
19. Remove the oil pump plate (A), the oil pump inner rotor (B), and the oil pump outer rotor (C).
20. Remove the 82 mm shim (A) from the transmission housing (B).
21. Remove the 8 mm special bolt (A), the 8 mm spring washer (B), the shift arm (C), the change lever (D), and the 16 x 23 x 5 mm dust seal (E).
