With R150, R150F and R151F Transmissions

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER DRIVEN GEAR (2WD), SHIFT LEVER RETAINER AND RESTRICT PINS
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE

4. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL
(a) Using a torx socket wrench, remove the screw plug from the extension housing or transfer adaptor.

(b) Using a magnetic finger, remove the spring and ball.

5.-i (2WD)
REMOVE EXTENSION HOUSING
(a) Remove the ten bolts.

(b) Remove the shift lever housing set bolt.
(c) Using a plastic hammer, tap the extension housing and remove the shift lever housing and shift and select lever.

5.-2 (4WD)
REMOVE TRANSFER ADAPTOR
(a) Using SST, remove the plug from the transfer adaptor.
SST 09043-38100

(b) Remove the shift lever housing set bolt.

(d) Remove the ten bolts.
(e) Using a plastic hammer, remove the transfer adaptor.

6. REMOVE FRONT BEARING RETAINER
(a) Remove the eight bolts.
(b) Using a plastic hammer, tap the front bearing retainer.

7. REMOVE BEARING SNAP RINGS
Using snap ring pliers, remove the two snap rings.

8. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE
(a) Using a brass bar and hammer, carefully tap off the transmission case.
(b) Remove the transmission case from the intermediate plate.

9. REMOVE MAGNET FROM INTERMEDIATE PLATE

10. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use two clutch housing bolts, plate washers and suitable nuts as shown.

CAUTION: Install the plate washers in reverse of normal. Increase or decrease plate washers so that the bolt tip and front tip surface of the nut are aligned.

(b) Mount the intermediate plate in a vise.

11. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS AND SPRINGS
(a) Using a torx socket wrench, remove the four plugs.

(b) Using a magnetic finger, remove the four springs and balls.

12. REMOVE SET BOLTS

13. REMOVE SNAP RINGS
Using two screwdrivers and a hammer, remove the three snap rings.

14. REMOVE SLOTTED SPRING PINS
Using a pin punch and hammer, drive out the two pins.

15. REMOVE NO. 5 SHIFT FORK SHAFT
Pull out No. 5 shift fork shaft from the intermediate plate.

16. REMOVE NO. 2 SHIFT FORK SHAFT AND SHIFT FORK
(a) Pull out No. 2 shift fork shaft from the intermediate plate.
(b) Remove No. 2 shift fork.
(c) Using a magnetic finger, remove the interlock pin from the intermediate plate.

17. REMOVE NO. 1 SHIFT FORK SHAFT
(a) Pull out No. 1 shift fork shaft from the intermediate plate.
(b) Using a magnetic finger, remove the interlock pins from the shaft hole and intermediate plate.

18. REMOVE NO. 3 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
(a) Pull out No. 3 shift fork shaft from the intermediate plate.
(b) Remove No. 1 shift fork.
(c) Using a magnetic finger, remove the interlock pin and locking ball from the shaft hole and intermediate plate.

19. REMOVE NO. 4 SHIFT FORK SHAFT, NO. 3 SHIFT FORK AND REVERSE SHIFT HEAD
(a) Pull out No. 4 shift fork shaft from the intermediate plate.
(b) Remove the reverse shift head and locking ball.
(c) Remove No. 3 shift fork.

20. REMOVE REVERSE SHIFT ARM FROM REVERSE SHIFT ARM BRACKET

21. REMOVE REVERSE SHIFT ARM BRACKET Remove the two bolts and the reverse shift arm bracket.

22.-i (2WD)
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using two screwdrivers and a hammer, tap out the rear snap ring.
(b) Remove the speedometer drive gear and ball.
(c) Using two screwdrivers and a hammer, tap out the front snap ring.

22.-2 (4WD)
REMOVE SLEEVE FROM OUTPUT SHAFT
Using SST, remove the sleeve from the output shaft.
SST 09213-36020

23. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using two screwdrivers and a hammer, tap out the snap ring.
(b) Using SST, remove the rear bearing.
SST 09950-20017

24. REMOVE SPACER

25. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust clearance.

Standard clearance:
0.10 - 0.35 mm (0.0039 - 0.0138 in.)
Maximum clearance:
0.40 mm (0.0157 in.)

26. REMOVE NO. 5 GEAR SPLINE PIECE, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR WITH NO. 3 HUB SLEEVE
(a) Engage the gear double meshing.
(b) Using a hammer and chisel, loosen the staked part of the nut.

(e) Using SST, remove No. 5 gear spline piece.
SST 09213-31021
(f) Remove the counter 5th gear with No. 3 hub sleeve.

27. REMOVE THRUST WASHER AND BALL

28. REMOVE REAR BEARING RETAINER Remove the four bolts and rear bearing retainer.

29. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.

30. REMOVE BEARING SNAP RING
Using snap ring pliers, remove the snap ring.

31. REMOVE OUTPUT SHAFT, COUNTER GEAR AND INPUT SHAFT AS A UNIT FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
(b) Remove the input shaft with the needle roller bearing from the output shaft.

32. REMOVE COUNTER REAR BEARING FROM INTERMEDIATE PLATE
Using SST, remove the counter rear bearing.
SST 09608-12010 (09608-00020, 09608-00050)

33. MEASURE EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.

1st gear
Standard clearance:
0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
2nd and 3rd gears
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)

34. REMOVE FIFTH GEAR, CENTER BEARING AND FIRST GEAR ASSEMBLY
(a) Using a press, remove the 5th gear, center bearing, thrust washer and 1st gear.
(b) Remove the synchronizer ring.
(c) Remove the straight pin and needle roller bearing.

(d) Remove the spacer.

35. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND SECOND GEAR ASSEMBLY
(a) Using two screwdrivers and a hammer, tap out the snap ring.

(b) Using a press, remove No. 1 hub sleeve, synchronizer ring and 2nd gear.
(c) Remove the needle roller bearing.

36. REMOVE NO. 2 HUB SLEEVE ASSEMBLY AND THIRD GEAR ASSEMBLY
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove No. 2 hub sleeve, synchronizer ring and 3rd gear.
(c) Remove the needle roller bearing.