Transmission Disassembly

Disassembly

Clutch Housing





5-speed model





6-speed model

Transmission Housing





5-speed model





6-speed model

NOTE:
- Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
- 6-speed model is shown, 5-speed model is similar.





1. Remove the detent bolts (A), springs, steel balls and back-up light switch (B).





2. Remove the Vehicle Speed Sensor (VSS) (A) and O-ring (B).





3. Remove the shift lever assembly (A), 8 x 14 mm dowel pins (B), clutch line clip bracket (C), and interlock bolt (D).





4. Remove the drain plug (A), filler plug (B), and 10 mm flange bolt (C).





5. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
6. Remove the harness bracket (A) (6-speed model only), the transmission hanger A (B), and the transmission hanger B (C).





7. Remove the 32 mm sealing cap (A).
8. Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.
9. Remove the transmission housing (C) and 14 x 20 mm dowel pins (D).





10. Remove the reverse lock cam (5-speed model only).





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





12. Remove the reverse shift fork.





13. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (C) from the clutch housing (D).
14. Remove the 28 mm spring washer (E) and 28 mm washer (F).





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





16. Remove the oil gutter plate (A), oil guide plate M, and 72 mm shim (B).