Part 1

DISASSEMBLY
1. REMOVE BACK-UP LIGHT SWITCH

Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)

2. 2WD: REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.

Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)

3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE
Remove the 9 bolts and clutch housing from the transmission case.

Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)

4. REMOVE CONTROL SHIFT LEVER RETAINER
a. Remove the 6 (2WD) or 4 (4WD) bolts.

Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

b. Remove the retainer and gasket (2WD) or oil deflector (4WD).
5. REMOVE 2 RESTRICT PINS

Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





6. 2WD: REMOVE EXTENSION HOUSING
a. Remove the shift lever housing set bolt.

Torque: 38 Nm (390 kgf-cm, 28 ft. lbs.)

b. Remove the 10 bolts.

Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

c. Using a plastic hammer, tap the extension housing, remove the shift lever housing and shift and select lever.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent





7. 4WD: REMOVE TRANSFER ADAPTOR
a. Remove the shift lever housing set bolt.

Torque: 38 Nm (390 kgf-cm, 28 ft. lbs.)

b. Remove the 10 bolts.

Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

c. Using a plastic hammer, tap the transfer adapter, remove the shift lever housing and the shift and select lever.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent





8. REMOVE FRONT BEARING RETAINER
a. Remove the 8 bolts.

Sealant: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 17 Nm (170 kgf-cm, 12 ft. lbs.)

b. Using a plastic hammer, tap the front bearing retainer.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent

9. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.





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

HINT: At the time of reassembly, please refer to the following item. Align the each bearing outer race, each fork shaft end and reverse idler gear shaft end with the case installation holes.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent

11. REMOVE MAGNET FROM INTERMEDIATE PLATE





12. MOUNT INTERMEDIATE PLATE IN VISE
a. Use the 2 clutch housing bolts, plate washers and suitable nuts, as shown.

HINT: Increase or decrease plate washers so that the bolt tip does not protrude from the nut.

b. Mount the intermediate plate in a vise.





13. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL AND SPRING
a. Using a hexagon wrench, remove the 4 plugs.

Sealant: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)

b. Using a magnetic finger, remove the 3 springs and balls.
14. REMOVE SHIFT FORK SET BOLT
Remove the 2 bolts from the shift forks No.1 and No.2.

Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)

15. REMOVE SLOTTED SPRING PIN
Using a pin punch and hammer, drive out the pin from the shift fork No.3.





16. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the 4 snap rings from each shift fork shaft.





17. REMOVE SHIFT FORK SHAFT NO.2 AND SHIFT FORK NO.2
a. Pull out the shift fork shaft No.2 from the shift forks No.1, No.2 and intermediate plate.
b. Remove the shift fork No.2 from the groove of hub sleeve No.2.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.





18. REMOVE SHIFT FORK SHAFT NO.1 AND SHIFT FORK NO.1
a. Pull out the shift fork shaft No.1 with the straight pin from the shift fork No.1 and intermediate plate.
b. Remove the shift fork No.1 from the groove of reverse gear.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.





19. REMOVE SHIFT FORK SHAFT NO.3 AND SHIFT FORK NO.3
a. Pull out the shift fork shaft No.3 from the shift fork No.3, reverse shift fork and intermediate plate.
b. Remove the shift fork No.3 from the groove of hub sleeve No.3.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.





20. REMOVE SHIFT FORK SHAFT NO. 4
a. Using a magnetic finger, remove the ball.
b. Pull out the shift fork shaft No.4 from the reverse shift fork and intermediate plate.

NOTICE: Take care of the ball in the reverse shift fork. It will spring out when you pull out the shift fork shaft No.4.

c. Using a magnetic finger, remove the spring from the reverse shift fork.





21. REMOVE REVERSE SHIFT FORK AND ARM
a. Remove the reverse shift fork and arm.

HINT: At the time of reassembly, please refer to the following item. Align the reverse shift arm to the pivot of the reverse shift arm bracket.

b. Using a screwdriver, remove the E-ring.
c. Separate the reverse shift fork and arm.
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.

Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





23. 2WD: REMOVE SPEEDOMETER DRIVE GEAR
a. Using 2 screwdrivers and a hammer, tap out the rear snap ring, and remove the drive gear and ball.
b. Using 2 screwdrivers and a hammer, tap out the front snap ring, and remove the drive gear.





24. REMOVE OUTPUT SHAFT REAR BEARING
a. Using 2 screwdrivers and a hammer, tap out the snap ring.





HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.








b. Using SST, remove the rear bearing.
SST 09950-40010





HINT: At the time of reassembly, please refer to the following items.

- 2WD: Using SST and a hammer, drive in a new bearing.
SST 09309-35010





- 4WD: Using SST and a hammer, drive in a new bearing.
SST 09316-60011 (09316-00011, 09316-00071)
25. REMOVE SPACER





26. INSPECT COUNTER 5TH 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 inch)
Maximum clearance: 0.40 mm (0.0157 inch)

27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND COUNTER 5TH GEAR WITH HUB SLEEVE NO.3





a. Using 2 screwdrivers and a hammer, tap out the snap ring.





HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.





b. Using SST, remove the gear spline piece No.5.
SST 09950-50010
c. Remove the counter 5th gear with the hub sleeve No.3.





HINT: At the time of reassembly, please refer to the following items.
^ Using SST and a hammer, drive in the gear spline piece No.5 with the synchronizer ring slots aligned with the shifting keys.
SST 09316-60011 (09316-00011)
^ When installing the gear spline piece No.5, support the counter gear in front with a 1.4 - 2.3 kg (3 - 5 lbs.) hammer or equivalent.

28. REMOVE THRUST WASHER AND BALL FROM COUNTER GEAR
29. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.

HINT: At the time of reassembly, please refer to the following item. Align the rear bearing retainer to the reverse idler gear shaft groove.

Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





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

HINT: At the time of the reassembly, please refer to the following item. Align the reverse shift arm to the reverse idler gear shaft.

31. REMOVE OUTPUT SHAFT CENTER BEARING SNAP RING
Using a snap ring expander, remove the snap ring.





32. REMOVE OUTPUT SHAFT AND COUNTER GEAR 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.





33. REMOVE COUNTER REAR BEARING FROM INTERMEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)





34. 2WD: IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
a. Using SST, remove the oil seal.
SST 09921-00010
b. Coat the lip of oil seal with MP grease.
c. Using SST, drive in a new oil seal.
SST 09201-10000 (09201-01080), 09950-70010 (09951-07150)

Drive in depth: 25 mm (0.98 inch)


REASSEMBLY
Reassembly is in the reverse order of disassembly.

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.


INPUT SHAFT





Components

Inspection
1. INSPECT SYNCHRONIZER RING





a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.





d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.8 mm (0.031 inch)

If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.


Replacement
IF NECESSARY, REPLACE INPUT SHAFT BEARING





a. Using a snap ring expander, remove the snap ring.
b. Using a press, remove the bearing.





c. Using Special Service Tool (SST) and a press, install a new bearing.
SST 09506-35010





d. Select a snap ring that allows minimum axial play.





e. Using a snap ring expander, install the snap ring.

OUTPUT SHAFT





Components

Disassembly








1. INSPECT EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.

Standard clearance:
1st gear: 0.15 - 0.45 mm (0.0059 - 0.0177 inch)
2nd and 3rd gears: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance:
1st gear: 0.50 mm (0.0197 inch)
2nd and 3rd gears: 0.30 mm (0.0118 inch)





2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each gear.

Standard clearance:
1st gear: 0.020 - 0.073 mm (0.0008 - 0.0029 inch)
2nd and 3rd gears: 0.015 - 0.068 mm (0.0006 - 0.0027 inch)
Maximum clearance:
1st gear: 0.160 mm (0.0063 inch)
2nd and 3rd gears: 0.160 mm (0.0063 inch)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER BEARING AND 1ST 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.





4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND GEAR ASSEMBLY
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
b. Using a press, remove the reverse gear assembly and 2nd gear assembly.
c. Remove the needle roller bearing.