6MT

Transmission Case
REMOVAL
1. Remove the manual transmission assembly from the vehicle.
2. Prepare the transmission for overhaul.
3. Remove the neutral position switch, back-up light switch and harness.
4. Remove the extension case.
5. Remove the transfer driven gear.
6. Remove the center differential.
7. Remove the oil guides G and H.





8. Remove the snap ring and flat washer from the selector arm area.





9. Using an ST, remove the neutral set spring and support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER





10. Lift the striking rod, and remove the spring pin.





11. Remove the selector arm No. 2 and the shifter arm.





12. Remove the transfer bearing holder.

NOTE: Using a general tool may cause damage. Remove the bolt using the ST.

ST 18663AA000 SOCKET





13. Remove the thrust washer on the main shaft section.
14. Remove the driven gear assembly shim and spacer.





15. Remove the snap ring.





16. Remove the pilot bolt.





17. Remove the holder reverse bolt.





18. Remove the transmission case.

NOTE: If the oil guide is caught between the shift fork, it may be difficult to remove the transmission case. Move the oil guide, then remove. Do not pull on the transmission case with excessive force.





19. Remove any remaining liquid gasket from the transmission case and adapter plate.

INSTALLATION
1. Check that the shifter fork and the interlock block are both shifted into the neutral position. If they are not, shift into the neutral position.





2. Apply liquid gasket to the adapter plate.
Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent





3. Install the transmission case.
4. By inspecting from the pilot bolt attachment hole, check that the interlock block and the reverse interlock block are aligned to the neutral position. If not aligned, remove the transmission case, and shift the shifter fork and interlock block to the neutral position.





5. Use a new gasket to temporarily attach the pilot bolt.
6. Affix the transmission case with the bolts and nuts.
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)
7. Tighten the pilot bolt.
Tightening torque: 34 N-m (3.5 kgf-m, 25.1 ft-lb)
8. Tighten the holder reverse bolt.
Tightening torque: 25 N-m (2.5 kgf-m, 18.4 ft-lb)
9. Install the snap ring, washer and collar of the driven gear assembly.





10. Attach the thrust washer to the main shaft.
11. Install the transfer bearing holder.
Tightening torque: 25 N-m (2.5 kgf-m, 18.4 ft-lb)
ST 18663AA000 SOCKET





12. When replacing the transfer bearing holder, select the appropriate transfer driven gear and thrust washer, and install to the extension case.
13. Install the selector arm No. 2 and the shifter arm.





14. Install a new spring pin.
15. Using the ST, install the neutral set spring.
ST1 18756AA000 CLAW
ST2 399893600 PLIER





16. Install the snap ring and flat washer to the selector arm area.





17. Install the oil guides G and H.





18. Install the center differential.
19. Install the transfer driven gear.
20. Install the extension case.
21. Install the neutral position switch, back-up light switch and harness.
22. Install the manual transmission assembly to the vehicle.

DISASSEMBLY
1. Remove the oil guides C, D, E and F.





2. Remove the harness bracket.





3. Remove the oil pan.





4. Remove any remaining liquid gasket from the transmission case and oil pan.

ASSEMBLY
1. Apply liquid gasket to the oil pan.
Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent





2. Install the oil pan.
Tightening torque: 6.4 N-m (0.7 kgf-m, 4.7 ft-lb)





3. Install the ball, valve spring and a new O-ring
Tightening torque:
T: 16 N-m (1.6 kgf-m, 11.8 ft-lb)





4. Install the oil guides C, D, E and F.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)





INSPECTION
1. If the sludge is accumulated in the oil pan, use a waste cloth to wipe it off completely.
2. Check that there is no damage on any parts. Replace damaged parts with new parts.