Disassembly

MAJOR COMPONENTS

Important Operations




4. Front Cover with Oil Seal
Remove the front cover with oil seal, then take out the belleville spring from the transmission case.




6. Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring from the outer circumference of the top gear shaft ball bearing.

Detent, Shift Fork Assembly And Interlock Pin:

MINOR COMPONENTS

Important Operations




3. Detent Ball
Use a magnetic hand to remove the detent balls from the intermediate plate.
Take care not to lose the detent balls.




7. 3rd-4th Shift Rod
8. 3rd-4th Shift Arm
9. 1st-2nd Shift Arm
1. Hold a round bar against the shift arm end. This will prevent damage to other components.




2. Use a spring pin remover to remove the shift arm spring pin from the shift arm and the shift rod.
Discard the used spring pin.
3. Move the 3rd-4th shift rod forward. Take care not to lose the interlock pins.




10. Interlock Pin
Carefully remove the reverse shifter rod forward to avoid losing the interlock pins.

NOTE: Remove the shifter rods carefully. Interlock pins are located between the shifter rod in the intermediate plate.




REVERSE GEAR AND 5TH GEAR

Important Operations




5. Snap Ring
6. Snap Ring
Use a pair of snap ring pliers to remove snap rings.




7. Thrust Ring
Remove the thrust ring.




10. Counter End Ball Bearing
11. Counter 5th Gear
Use the gear remover to remove the counter 5th gear with the ball bearing.
Gear Remover : J-22888




13. 5th Gear
14. Needle Bearing
Remove the needle bearing (2 piece type).




16. Mainshaft Lock Nut and Washer
1. Engage the 3rd-4th synchronizer with the 3rd gear.
2. Engage the 1st-2nd synchronizer with the 1st gear.
3. Attach the holding fixture to the mainshaft and the countergear.
Holding Fixture : J-29768




4. Use the lock nut wrench to remove the lock nut
Lock Nut Wrench : J-36629




17. Rev. - 5th Synchronizer Assembly
1. Remove the synchronizer assembly as a set.
2. Disassemble the synchronizer assembly.
1. Springs
2. Sleeve
3. Clutch Hub
4. Inserts




27. Bearing Snap Ring
1. Insert the snap ring pliers (1) into the countergear bearing snap ring hole (2).
The snap ring hole is in the intermediate plate (3)
2. Use the snap ring pliers to force open the countergear bearing snap ring.
Tap on the front of the intermediate plate. The ball bearing snap ring will come free.




28. Bearing Snap Ring
29. Intermediate Plate
1. Insert the snap ring pliers into the mainshaft bearing snap ring hole.
The snap ring hole is in the intermediate plate (1)
2. Use the snap ring pliers (2) to force open the mainshaft bearing snap ring (3)
Hold the snap ring open with the pliers.
3. Push the intermediate plate toward the rear of the transmission to remove it.
The ball bearing snap ring will come free.




TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR

Important Operations




1. Top Gear Shaft Snap Ring
2. Top Gear Shaft
3. Ball Bearing
1. Use a pair of snap ring pliers to remove the snap ring.
2. Use a bench press and the bearing remover to remove the ball bearing.
Bearing Remover : J-22912-01




7. 3rd-4th Synchronizer Assembly
1. Remove the synchronizer assembly as a set.
2. Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts




11. Mainshaft Ball Bearing
Use a bench press and the bearing remover to remove the ball bearing.
Bearing Remover : J-22912-01




17. 1st-2nd Synchronizer Assembly
1. Remove the synchronizer assembly as a set.
2. Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts




22. Rear Ball Bearing
24. Front Ball Bearing
Use a bench press and the bearing remover to remove the ball bearing.
Bearing Remover J-22912-01