Part 1

Disassembly





1. Removal of manual transmission filler plug
(1) Remove the manual transmission filler plug and the gasket.





2. Removal of manual transmission drain plug
(1) Remove the manual transmission drain plug and the gasket.





3. Removal of clutch release fork support
(1) Remove the clutch release fork support from the clutch housing.





4. Removal of back-up light switch ASSY
(1) Release the 3 clamps.





(2) Remove the back-up light switch ASSY and the gasket.





5. Removal of neutral switch
(1) Release the clamp.





(2) Remove the neutral switch and the gasket.





6. Removal of wiring harness clamp bracket
(1) Remove the bolt, and then remove the wiring harness clamp bracket.





7. Removal of lock ball pin
(1) Remove the head straight screw plug, compression spring, and lock ball pin.





8. Removal of holder
(1) Remove the holder, compression spring, and lock ball pin.





9. Removal of transmission extension housing SUB-ASSY (MTM)
(1) Remove the bolt.





(2) Remove the 8 bolts and the clump.

Captions in illustration








(3) Remove the transmission extension housing SUB-ASSY (MTM).

CAUTION:
^ Do not damage the transmission extension housing SUB-ASSY (MTM).
^ Be sure to remove the transmission extension housing SUB-ASSY (MTM) with the shift position in neutral status.





10. Removal of extension housing rear oil seal
(1) Remove the extension housing rear oil seal.

Captions in illustration





CAUTION:
Do not damage the transmission extension housing SUB-ASSY (MTM).

NOTE:
Remove while applying a cloth to prevent damage to the transmission extension housing SUB-ASSY (MTM).





11. Removal of extension housing dust deflector
(1) Remove the extension housing dust deflector.





12. Removal of transmission extension housing oil seal
(1) Remove the transmission extension housing oil seal.

Captions in illustration





CAUTION:
Do not damage the transmission extension housing SUB-ASSY (MTM).

NOTE:
Remove while applying a cloth to prevent damage to the transmission extension housing SUB-ASSY (MTM).





13. Removal of extension housing oil receiver pipe No.2
(1) Remove the extension housing oil receiver pipe No.2.





14. Removal of extension housing oil receiver pipe No.1
(1) Remove the bolt to remove the extension housing oil receiver pipe No.1 and the stopper plate.





(2) Remove the straight pin.





15. Removal of shift shaft
(1) Slide and remove the shift shaft and the shift inner lock block No.1.





16. Removal of shift inner lock block No.1.
(1) Remove the shift inner lock block No.1 from the shift shaft.





17. Removal of shift inner lever FR
(1) Remove bolt, then remove the shift inner lever FR from the shift shaft.

CAUTION:
Verify the direction of the parts.





18. Removal of head straight screw plug
(1) Remove the 3 head straight screw plugs.





(2) Remove the 2 compression springs and the 2 balls.





19. Removal of shift arm
(1) Remove the E-ring.

CAUTION:
Hold the E-ring with a cloth to prevent it from flying out.





(2) Remove the shift arm.





20. Removal of gear shift fork shaft No.3
(1) Remove the gear shift fork shaft No.3.

CAUTION:
^ Do not drop the ball of the 5th shift head.
^ The ball of the transmission case may fall in the transmission case. If the ball falls, pick the ball up when removing the transmission case.

(2) Remove the ball of the 5th shift head.





(3) Remove the ball.





21. Removal of 5th shift head
(1) Remove the shaft snap ring.

CAUTION:
Hold the shaft snap ring with a cloth to prevent it from flying out.





(2) Remove the washer.





(3) Remove the 5th shift head, then remove the ball and the compression spring.

CAUTION:
Do not slide the 5th shift head to prevent the ball and the compression spring from falling.





22. Check of counter shaft 6th gear thrust clearance
(1) Use the SST to check the thrust clearance.
SST 09350-20015 (09350-06120), 498255400
Standard value: 0.10 to 0.40 mm {0.00394 to 0.0157 in}
Limit: 0.40 mm {0.0157 in}

NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear, transmission clutch hub No.4, 6th gear thrust washer, needle roller bearing, and counter shaft with new ones.





23. Check of counter shaft 6th gear radial clearance
(1) Check the radial clearance.
Standard value: 0.015 to 0.068 mm {0.000590 to 0.00268 in}
Limit: 0.068 mm {0.00268 in}

NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear, needle roller bearing, and counter shaft with new ones.