Manual Transmission Disassembly

Manual Transmission Disassembly

Exploded View-Clutch Housing





Exploded View-Transmission Housing





NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Remove the release bearing and the release fork.

2. Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), the steel balls (D), and the back-up light switch (E).





3. Remove the 20 mm bolt (F) and the 20 mm sealing washer (G).

4. Remove the interlock bolt (A), the change lever assembly (B), and the 8 x 14 mm dowel pins (C).






5. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), and the sealing washers (D).





6. Remove the output shaft (countershaft) speed sensor (E), the plain washer (F), and the O-ring (G).

7. Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them with transmission hanger A, transmission hanger B, and the harness bracket (C).






8. Remove the 32 mm sealing cap (A).





9. While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C). Release the snap ring pliers, and remove the transmission housing and the three 14 x 20 mm dowel pins (D).

10. Remove the baffle plate (A).






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






12. Remove the reverse shift fork (A).






13. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

NOTE: Do not apply tape thick to damage the oil seal.





14. Remove the 28 mm spring washer (E) and the 28 mm washer (F).

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






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