Transmission Unit ASSY: Disassembly

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

G12588066

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Removal of manual transmission filler plug
1. Remove the manual transmission filler plug and the gasket.
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Removal of manual transmission drain plug
1. Remove the manual transmission drain plug and the gasket.
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Removal of clutch release fork support
1. Remove the clutch release fork support from the clutch housing.
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Removal of back-up light switch ASSY

Release the 3 clamps.

G12588070

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Remove the back-up light switch ASSY and the gasket.

G12588071

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Removal of neutral switch

Release the clamp.

G12588072

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Remove the neutral switch and the gasket.

G12588073

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Removal of wiring harness clamp bracket
1. Remove the bolt, and then remove the wiring harness clamp bracket.
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Removal of lock ball pin
1. Remove the head straight screw plug, compression spring, and lock ball pin.
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Removal of holder
1. Remove the holder, compression spring, and lock ball pin.
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Removal of transmission extension housing SUB-ASSY (MTM)

Remove the bolt.

G12588077

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Remove the 8 bolts and the clump.

G12588078

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Remove the transmission extension housing SUB-ASSY (MTM).
CAUTION:
- Do not damage the transmission extension housing SUB-ASSY (MTM).
- Be sure to remove the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.

G12588079

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Removal of extension housing rear oil seal
1. Remove the extension housing rear oil seal.
  CAUTION: Do not damage the transmission extension housing SUB-ASSY (MTM).
  
  NOTE: Remove while applying a cloth to prevent damage to the transmission extension housing SUB-ASSY (MTM).
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Removal of extension housing dust deflector
1. Remove the extension housing dust deflector.
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Removal of transmission extension housing oil seal
1. Remove the transmission extension housing oil seal.
  CAUTION: Do not damage the transmission extension housing SUB-ASSY (MTM).
  
  NOTE: Remove while applying a cloth to prevent damage to the transmission extension housing SUB-ASSY (MTM).
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Removal of extension housing oil receiver pipe No. 2
1. Remove the extension housing oil receiver pipe No. 2.
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Removal of extension housing oil receiver pipe No. 1

Remove the bolt to remove the extension housing oil receiver pipe No. 1 and the stopper plate.

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Remove the straight pin.

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Removal of shift shaft
1. Slide and remove the shift shaft and the shift inner lock block No. 1.
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Removal of shift inner lock block No. 1.
1. Remove the shift inner lock block No. 1 from the shift shaft.
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Removal of shift inner lever FR
1. Remove bolt, then remove the shift inner lever FR from the shift shaft.
  CAUTION: Verify the direction of the parts.
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Removal of head straight screw plug

Remove the 3 head straight screw plugs.

G12588089

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Remove the 2 compression springs and the 2 balls.

G12588090

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Removal of shift arm

Remove the E-ring.

CAUTION: Hold the E-ring with a cloth to prevent it from flying out.

G12588091

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Remove the shift arm.

G08554932

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Removal of gear shift fork shaft No. 3

Remove the gear shift fork shaft No. 3.
CAUTION:
- Do not drop the ball of the 5th shift head.
- The ball of the transmission case may fall in the transmission case. If the ball falls, pick the ball up when removing the transmission case.

Remove the ball of the 5th shift head.

G12588093

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Remove the ball.

G12588094

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Removal of 5th shift head

Remove the shaft snap ring.

CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.

G12588095

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Remove the washer.

G12588096

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Remove the 5th shift head, then remove the ball and the compression spring.
CAUTION: Do not slide the 5th shift head to prevent the ball and the compression spring from falling.

G12588097

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Check of counter shaft 6th gear thrust clearance
1. Use the SST to check the thrust clearance.
  SST 09350-20015 (09350-06120), 498255400
  
  Standard value: 0.10 to 0.40 mm {0.00394 to 0.0157 in}
  
  Limit: 0.40 mm {0.0157 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 6th gear, transmission clutch hub No. 4, 6th gear thrust washer, needle roller bearing, and counter shaft with new ones.
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Check of counter shaft 6th gear radial clearance
1. Check the radial clearance.
  Standard value: 0.015 to 0.068 mm {0.000590 to 0.00268 in}
  
  Limit: 0.068 mm {0.00268 in}
  
  NOTE: If the value exceeds the limit, replace the counter shaft 6th gear, needle roller bearing, and counter shaft with new ones.
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Removal of transmission clutch hub No. 4

Remove the shaft snap ring.

CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.

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Use the SST to remove the transmission clutch hub No. 4 together with the transmission hub sleeve No. 4, gear shift fork No. 4, and gear shift fork shaft No. 2 as a unit.

SST 09950-30012 (09951-03010, 09953-03010, 09956-03010)

CAUTION: Verify the direction of the parts.

G10214882

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Removal of gear shift fork No. 4
1. Remove the bolt, then remove the gear shift fork No. 4 from the gear shift fork shaft No. 2.
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Removal of transmission hub sleeve No. 4

Remove the hole snap ring.

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Remove the transmission hub sleeve No. 4, then remove the 3 synchromesh shifting keys No. 1, 3 synchromesh shifting key springs No. 1, and 3 balls from the transmission clutch hub No. 4.
CAUTION:
- Keep the synchromesh shifting keys No. 1, synchromesh shifting key springs No. 1, and balls from flying out using a cloth.
- Be careful not to deform the synchromesh shifting key springs No. 1.
- Verify the direction of the parts.

NOTE: Perform the work without displacing the positions of the transmission clutch hub No. 4 and synchromesh shifting keys No. 1.

G12588104

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Removal of synchronizer ring No. 2
1. Remove the synchronizer ring No. 2.
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Removal of counter shaft 6th gear
1. Remove the counter shaft 6th gear.
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Removal of needle roller bearing
1. Remove the needle roller bearing.
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Removal of 6th gear thrust washer

Remove the 6th gear thrust washer.

CAUTION: Verify the direction of the parts.

G12588108

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Remove the straight pin.

G12588109

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Removal of gear shift head No. 2
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 2 from the gear shift fork shaft No. 2.
  CAUTION:
  - Hold the slotted spring pin with a cloth to prevent it from flying out.
  - Do not drop the slotted spring pin from the fork shaft hole into the inside.
  - Verify the direction of the parts.
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Removal of gear shift head No. 1.
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 1 from the gear shift fork shaft No. 1.
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Removal of gear shift head No. 3
1. Remove the slotted spring pin.
2. Remove the gear shift head No. 3 from the gear shift fork shaft No. 3.
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Removal of bearing retainer RR

Remove 4 TORX bolts to remove the bearing retainer RR.

G12588113

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Remove the shift arm pivot.

G08554954

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Removal of transmission case

Use the SST to remove the shaft snap ring.

SST 499895400

G12588115

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

(Transmission case side)

G12588116

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Remove the 9 bolts and the clump.

G12588117

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Remove the transmission case.
CAUTION: Do not damage the transmission case.

G12588118

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Removal of oil receiver pipe
1. Remove the oil receiver pipe.
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Removal of bearing retainer FR
1. Remove the 7 bolts, then remove the bearing retainer FR.
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Removal of transmission front bearing retainer oil seal
1. Remove the transmission front bearing retainer oil seal.
CAUTION: Do not damage the bearing retainer FR.

NOTE: Remove while applying a cloth to prevent damage to the bearing retainer FR.

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Removal of counter shaft

Use the SST to remove the 2 shaft snap rings.

SST 499895400

NOTE: Remove the shaft snap rings on the input shaft side and the counter shaft side.

G12588122

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Remove the bolt and the gasket to free the reverse idler gear and the reverse idler gear shaft. (Clutch housing side)

G12588123

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Remove the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, gear shift fork shaft No. 1, gear shift fork shaft No. 2, and gear shift fork shaft No. 3 as a unit by hitting them from the clutch housing side with the handle of a hammer.

G12588124

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Removal of gear shift fork shaft No. 2

Remove the shaft snap ring.

CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.

G12588125

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Remove the bolt, then remove the gear shift fork shaft No. 2.

G12588126

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Removal of gear shift fork shaft No. 1

Remove the shaft snap ring.

CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.

G12588127

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Remove the gear shift fork shaft No. 1 and the gear shift fork No. 1 as a unit.

G12588128

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Remove the shaft snap ring.

CAUTION: Hold the shaft snap ring with a cloth to prevent it from flying out.

G12588129

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Remove the bolt, then remove the gear shift fork shaft No. 1.

G12588130

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Removal of gear shift fork shaft No. 3
1. Remove the bolt, then remove the gear shift fork shaft No. 3.
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Removal of input shaft
1. Remove the input shaft from the output shaft.
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Check of reverse idler gear radial clearance
1. Secure the reverse idler gear shaft with a vise and check the radial clearance.
  Standard value: 0.040 to 0.082 mm {0.00157 to 0.00323 in}
  
  Limit: 0.082 mm {0.00323 in}
  
  NOTE: If the value exceeds the limit, replace the reverse idler gear and the reverse idler gear shaft with new ones.
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Removal of reverse idler gear shaft
1. Remove the reverse idler gear shaft from the reverse idler gear.