Transmission Disassemble

WARNING: This page is about a different variant/trim than selected.

Special Tools

DT-586 Universal Seal Remover
DT-7004 Sliding Hammer
DT-49084 Input Shaft Holder
DT-50182 Backup Light Switch Remover/Installer
DT-50500 Differential Bearing Cup Remover
DT-50504 Counter Shaft Bearing Cup Remover/Installer
DT-50505 Bridge
DT-727 Remover
GE-328 - B Puller

For equivalent regional tools, refer to Special Tools .

Remove the manual transmission. Refer to Transmission Replacement (With 1.0L Engine) Transmission Replacement (With 1.4L Engine) .
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Remove the selector and shift lever cable bracket bolts (1).
Remove the selector and shift lever cable bracket (2).
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Remove the backup light switch (2) using the DT-50182 backup lamp switch remover/installer (1).
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If equipped, remove the vehicle speed sensor assembly bolt (1).
If equipped, remove the vehicle speed sensor assembly (2).
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If equipped, remove the input speed sensor bolt (1).
If equipped, remove the input speed sensor (2).
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Remove the clutch actuator cylinder pipe elbow clip (1).
Remove the clutch actuator cylinder pipe elbow (2).
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Remove the clutch actuator cylinder clip (1).
Remove the clutch actuator cylinder pipe (2) and sleeve (3) from transmission right side case.

NOTE:

Push the key (4) of the clutch actuator cylinder pipe sleeve using a screw driver.

Remove the clutch actuator cylinder pipe sleeve (3) from the clutch actuator cylinder pipe.
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Remove the 3 clutch actuator cylinder bolts (1).
Remove the clutch actuator cylinder (2).
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Remove 8 side cover bolts (1).
Remove side cover (2) using a rubber hammer.
Remove the sealant on the side cover and the transmission case.
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Remove the input shaft circlip (1).
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Remove the 5th gear shift fork pin (1) using a pin punch and a hammer.
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Pull and remove the 5th gear fork (1) and the synchronizer sleeve (2) together.
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Remove the 5th gear synchronizer hub plate (4) from the 5th synchronizer hub.
Remove the 5th synchronizer hub (3), 2 levers (2) and the synchronizer ring (1).
Fig 1: Identifying Input Shaft 5th Gear
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Pull and remove the input shaft 5th gear (1).
Remove the input shaft 5th gear bearing (2).
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Hold the input shaft using the DT-49084 input shaft holder (1).
Remove the caulking and the counter shaft 5th gear nut (2).
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Remove the counter shaft 5th gear (1) from the counter shaft.
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Remove 6 left case plate screws (1).
Remove the left case plate (2).
Remove the countershaft bearing shim (3).
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NOTE:
The case (Left) cannot be removed without removing the reverse idle gear shaft bolt.

Remove the reverse idle gear shaft bolt (1) and gasket (2).
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NOTE:
Certainly remove the shift interlock bolt. Otherwise, shift control housing assembly cannot be removed.

Remove the shift interlock washer (2) and bolt (1).
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NOTE:
Shift the transmission into NEUTRAL.

Remove the 4 shift control housing bolts (1).
Remove the shift control housing assembly (2).
Remove the sealant on the shift control housing and the transmission case.
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Remove the 2 bolts (1) from the right case side.
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Remove 13 bolts (1) from the left case side.
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NOTE:
Inspect the detent for damage. If the detent is damaged, remove and discard the detent.

Remove the shift shaft detent (3) using the DT-727 remover (1) and GE-328 - B Puller (2).
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Remove the left side case by hitting with a rubber hammer lightly.
Remove the sealant on the case.
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Remove the reverse gear shift lever washer (2) and bolts (1).
Remove the reverse gear shift lever (3).
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Remove the reverse idle gear (2) and shaft (1).
Remove the reverse idle gear (2) from the shaft assembly.
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Remove the 5th and reverse gear shift shaft (1).
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NOTE:
Be careful not to damage the teeth of the counter shaft pinion and the differential ring gear.

Remove the gear unit and the shift shaft assembly (1) together.
Remove the high and the low speed shift shaft assembly from the gear unit.
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Insert a wooden prying device into the lower side of the differential.
Remove the differential assembly (1) by moving it right and left.
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NOTE:
Push the key of the oil gutter from the left side case using a screw driver.

Remove the oil gutter (1).
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Remove the counter shaft bearing cup (2) using the DT-50504 counter shaft bearing cup remover/installer (1) and a hammer.
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Remove the differential left side bearing cup (3) using the DT-50500 differential bearing cup remover (1) and the DT-50505 bridge (2).
Remove the differential left side bearing shim (4).
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NOTE:
Do not reuse the differential right side oil seal.

Remove the differential right side oil seal (1) using the DT-7004 sliding hammer and the DT-586 seal remover hook (2).
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NOTE:
Do not reuse the input shaft right side seal.

Remove the input shaft right side seal (1) using a screwdriver.
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Remove the differential right side bearing cup (3) using the DT-50500 differential bearing cup remover (1) and the DT-50505 bridge (2).
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NOTE:
Do not reuse the differential left side oil seal.

Remove the differential left side oil seal (1) using the DT-586 seal remover hook (2) and DT-7004 sliding hammer (3).