1. Disassembly
Transmission DisassemblyClutch Housing: 2002-2004 5-speed models:
Clutch Housing: 2005-2006 5-speed models:
Clutch Housing: 2002-2004 6-speed models:
Clutch Housing: 2005-2006 6-speed models:
Transmission Housing: 2002-2004 5-speed models:
Transmission Housing: 2005-2006 5-speed models:
Transmission Housing: 2002-2004 6-speed models:
Transmission Housing: 2005-2006 6-speed models:
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. 2002-2004 models: Remove the vehicle speed sensor (VSS) (A) and O-ring (B).
3. 2005-2006 models: Remove the 20 mm bolt (A) and the 20 mm washer (B).
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. 2002-2004 models: Remove the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C).
6. 2005-2006 models: 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).
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. 5-speed model: Remove the reverse lock cam.
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 the countershaft assembly (B) with the shift forks (C) from the clutch housing (D).
16. Remove the 28 mm spring washer (E) and the 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).
