Part 1

R155 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: DISASSEMBLY

1. REMOVE MANUAL TRANSMISSION FILLER PLUG





(a) Remove the transmission filler plug and gasket from the transmission case.

2. REMOVE DRAIN PLUG SUB-ASSEMBLY





(a) Remove the transmission drain plug and gasket from the transmission case.

3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY





(a) Remove the clutch release fork and clutch release bearing from the clutch housing.

4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY





(a) Remove the release bearing hub clip, and then remove the clutch release bearing from the clutch release fork.

5. REMOVE RELEASE FORK SUPPORT





(a) Remove the release fork support from the clutch housing.

6. REMOVE CLUTCH RELEASE FORK BOOT





(a) Remove the clutch release fork boot from the clutch housing.

7. REMOVE CLUTCH HOUSING





(a) Remove the 9 bolts.

(b) Using a plastic hammer, remove the clutch housing from the transmission case.





8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY





(a) Using SST, remove the back-up light switch assembly and the gasket from the transmission case.

SST : 09817-16011

9. REMOVE SPEEDOMETER SENSOR

(a) Remove the bolt and speedometer sensor from the extension housing.

(b) Remove the O-ring from the speedometer sensor.

10. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY





(a) Remove the 6 bolts.

(b) Remove the floor shift control shift lever retainer gasket from the extension housing.

(c) Remove the control shift lever retainer gasket from the extension housing.

11. REMOVE REVERSE RESTRICT PIN





(a) Remove the 2 reverse restrict pins from the extension housing or transfer adapter.

12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY





(a) Remove the shift lever housing set bolt from the shift lever housing.

(b) Remove the 10 bolts.





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

13. REMOVE OIL RECEIVER





(a) Remove the oil receiver from the extension housing.

14. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

(a) Remove the bolt and oil receiver pipe from the extension housing.

15. REMOVE REVERSE RESTRICT PIN ASSEMBLY

(a) Using a "Torx" socket wrench T40, remove the reverse restrict pin plug from the transfer adapter.

(b) Using a pin punch (5 mm) and a hammer, remove the reverse restrict pin slotted from the transfer adapter or extension housing.





(c) Remove the reverse restrict pin from the transfer adapter or extension housing.





16. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL





(a) Using a screwdriver, remove the extension housing oil seal from the extension housing.

17. REMOVE FRONT BEARING RETAINER





(a) Remove the 8 bolts.

(b) Using a brass bar and a hammer, remove the front bearing retainer from the transmission case.





18. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL





(a) Fix the front bearing retainer in a vise, between aluminum plate.

(b) Using SST, remove the transmission front bearing retainer oil seal.

SST : 09308-00010

19. REMOVE FRONT BEARING SHAFT SNAP RING





(a) Using a snap ring expander, remove the front bearing shaft snap ring from the transmission case.

20. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING





(a) Using a snap ring expander, remove the counter gear front bearing snap ring No. 1 from the transmission case.

21. REMOVE MANUAL TRANSMISSION CASE





(a) Using a brass bar and a hammer, remove the transmission case from the intermediate plate.

22. REMOVE TRANSMISSION MAGNET





(a) Remove the transmission magnet from the intermediate plate.

23. FIX INTERMEDIATE PLATE





(a) Fix the intermediate plate in a vice between aluminum plates.

24. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT





(a) Using a "Torx" socket wrench T40, remove the shift detent ball spring seat No. 1 from the intermediate plate.

(b) Using a magnetic finger, remove the shift detent ball low side compression spring and the shift detent ball from the intermediate plate.





(c) Using a "Torx" socket wrench T40, remove the 3 shift detent ball spring seats No. 1 from the intermediate plate.





(d) Using a magnetic finger, remove the 2 shift detent ball low side compression springs and the 2 shift detent balls from the intermediate plate.





25. REMOVE NO. 2 GEAR SHIFT FORK SHAFT





(a) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 2.

NOTICE:
Use a shop rag to prevent the snap ring from flying off.

(b) Remove the shift fork set bolt from the gear shift fork No. 2.





(c) Remove the gear shift fork shaft No. 2 from the intermediate plate.





(d) Remove the gear shift fork No. 2 from the transmission hub sleeve No. 2.





(e) Using a magnetic finger, remove the shift interlock No. 1 roller and the shift interlock pin (ball) from the intermediate plate.