Removal

Synchro Ring and Gear Inspection





Removal

1. M/T Change Lever Assembly





1. Remove the interlock bolt (A).

2. Remove any old liquid gasket from the interlock bolt.

3. Remove the change lever assembly (B).

4. Remove the 8 x 14 mm dowel pins (C).

2. Back-Up Light Switch





1. Remove the back-up light switch (A).

2. Remove any old liquid gasket.

3. Output Shaft (Countershaft) Speed Sensor





1. Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

4. Transmission Housing





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





2. Remove the 10 mm flange bolt (A) and the sealing washer (B).





3. Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them with transmission hanger A, transmission hanger B, and the harness bracket (C).





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

5. While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

6. Release the snap ring pliers, and remove the transmission housing.

7. Remove the 14 x 20 mm dowel pins (D).

5. Reverse Shift Fork





1. Remove the reverse shift fork (A).

6. Baffle Plate





1. Remove the baffle plate (A).

7. Reverse Idler Gear





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

8. M/T Mainshaft and Countershaft and Shift Fork Assembly





1. Apply a thin layer of tape to the mainshaft splines to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

2. Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

3. Remove the 28 mm washer (E).

4. Remove the 28 mm spring washer (F).

9. M/T Mainshaft 5th and 6th Gear





1. Remove the angular ball bearing (A) using a commercially available bearing separator (B) and a commercially available bearing puller (C).





2. Support 5th gear (A) on steel blocks.

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

3. Press the mainshaft out of the 5th/6th synchro hub (B).

10. M/T Mainshaft 3rd and 4th Gear





1. Support 3rd gear (A) on steel blocks.

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

2. Press the mainshaft out of the 3rd/4th synchro hub (B).

11. M/T Countershaft





1. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

2. Remove the special bolt (B) (left-hand threads).





3. Support 6th gear (A) on steel blocks (B).

4. Use a press (C) and an attachment (D) to press the countershaft out of the ball bearing and 6th gear.

5. Remove the 35 mm shim.





6. Support 4th gear (A) on steel blocks (B).

7. Use the press (C) and an attachment (D) to press the countershaft (E) out of 4th gear and 5th gear.





8. Support 2nd gear (A) on steel blocks (B).

9. Use the press (C) and an attachment (D) to press the countershaft (E) out of 2nd gear and 3rd gear.