1. Disassembly
Transmission DisassemblyExploded View-Clutch Housing
5-speed model (2005 model)
Exploded View-Clutch Housing
6-speed model (2005 model)
Exploded View-Transmission Housing
5-speed model (2005 model)
Exploded View-Transmission Housing
6-speed model (2005 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 the back-up light switch (B).
2. Remove the vehicle speed sensor (VSS) (A) and O-ring (B) (2002-2004 models).
3. Remove the 20 mm bolt (A) and the 20 mm washer (B) (2005 model).
4. Remove the change lever assembly (A), the 8 x 14 mm dowel pins (B), the clutch line clip bracket (C), and the interlock bolt (D).
5. Remove the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C) (2002-2004 models).
6. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), the output shaft (countershaft) speed sensor (D), the plain washer (5-speed model) (E), and the O-ring (F) (2005 model).
7. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
8. Remove the harness bracket (A) (6-speed model only), the transmission hanger A (B), and the transmission hanger B (C).
9. Remove the 32 mm sealing cap (A).
10. 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.
11. Remove the transmission housing (C) and the 14 x 20 mm dowel pins (D).
12. Remove the reverse lock cam (5-speed model only).
13. Remove the reverse idler gear (A) and the reverse gear shaft (B).
14. Remove the reverse shift fork.
15. 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).
16. Remove the 28 mm spring washer (E) and 28 mm washer (F).
17. Remove the differential assembly (A) and the magnet (B).
18. Remove the oil gutter plate (A), the oil guide plate M, and the 72 mm shim (B).