Manual Transmission Unit Disassembly
Manual Transmission Unit DisassemblyReference: Manual Transmission Assembly Dismounting and Remounting: H27 Engine Model
1) Remove clutch release bearing (1), release fork (2) and clutch housing (3).
2) Remove back-up light switch (1).
3) Remove return spring low bolt (1) and return spring reverse bolt (2).
4) Remove transmission to transfer bolt (1).
5) Disconnect gear shift inner lever edge (2) from gear shift shaft (4), and remove rear case (3) tapping transmission rear case's end by plastic hammer.
6) Drive spring pin (1) out by using special tool and then remove gear shift inner shaft (2) and gear shift inner lever (3) from rear case.
Special Tool
(A): 09922-85811
7) Remove input shaft bearing retainer (1).
8) Remove C-rings (1) of input shaft bearing and C-ring (2) of countershaft front bearing.
Special Tool
(B):09900-06107
9) Tapping transmission front case (1) flanges with plastic hammer. Remove transmission front case.
10) Set transmission intermediate case on vise securely.
NOTE: Use aluminum plates between vise and intermediate case to protect intermediate case against damage.
11) Remove locating screws (1), locating springs (2) and locating ball (3) as shown in the figure.
12) Remove low speed gear shift fork bolt (1) and high speed gear shift fork bolt (2).
13) Remove circlips (1) from high speed gear shift shaft (2) and low gear shift shaft (3) using flat head screw drivers (4) or the like.
14) Remove high speed gear shift shaft (2) and high speed gear shift fork (1).
15) Remove interlock pin (1) and straight pin (2) using magnet (3).
16) Remove low speed gear shift shaft (2) and low speed gear shift fork (1).
17) Remove interlock pin (1) by using magnet (2).
18) Remove circlips (1) from 5th gear shift shaft (2) and 5th & reverse guide shaft (3) using flat head screw drivers (4) or the like.
19) Drive spring pin (1) out from 5th gear shift fork (2) using special tool.
Special Tool
(A): 09922-85811
20) Remove 5th gear shift shaft (1) and 5th gear shift fork (2).
21) Remove interlock pin (1) from intermediate case (2) using magnet (3).
22) Remove ball (4) from reverse shift fork (5) using magnet (3).
23) Pull out 5th & reverse guide shaft (1) from intermediate case (2).
NOTE: When pulling 5th & reverse guide shaft (1), place hand so as to catch ball (3) jumping out of reverse gear shift fork (4).
24) Remove compression spring (5) from reverse gear shift fork (4) using magnet.
25) Remove reverse gear shift fork (4) with reverse gear shift arm (6) from reverse gear shift arm bracket (7).
26) Remove circlip (1), and then remove reverse gear shift arm (2) from reverse gear shift fork (3), if necessary.
27) Remove reverse gear shift arm bracket (1) from intermediate case (2).
28) Remove circlip (1) from countershaft (2) using flat head screw drivers (3) or the like.
29) Remove 5th speed synchronizer dog (1) using special tools and adjustable angle wrench (2).
Special Tool
(A): 09944-36011
(B): 09913-85230
30) Remove 5th & reverse synchronizer ring.
31) Pull off 5th & reverse synchronizer sleeve (1), countershaft 5th gear assembly (2) and needle bearing (3) together from countershaft (4).
32) Remove synchronizer key spring (1) and balk levers (2) from countershaft 5th gear (3).
33) Remove 5th & reverse synchronizer sleeve (4) from countershaft 5th gear (3).
34) Remove circlip (1) using special tool, and then remove plate spring (2).
Special Tool
(A): 09900-06107
35) Remove thrust washer (2) and pin (1).
36) Remove main shaft and countershaft bearing plate (1).
37) Remove reverse idle gear (1) and shaft (2).
38) Remove C-ring (1) of countershaft rear bearing using special tool.
Special Tool
(B): 09900-06107
39) Remove countershaft rear bearing (1) from intermediate case using rod (2) and hammer, and then remove countershaft (3).
40) Remove input shaft assembly (1) with 4th gear synchronizer ring from main shaft assembly (2).
NOTE: When removing input shaft, be careful not to drop roller bearing.
41) Remove C-ring (1) of main shaft bearing using flat head screwdrivers (2) or the like and pull out main shaft assembly (3).
NOTE: If intermediate case (4) is engaged with bearing firmly, tap front face of intermediate case (4) with plastic hammer lightly as it will cause main shaft assembly (3) to come off forward.