Part 2

R155 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: DISASSEMBLY - Continued

26. REMOVE NO. 1 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. 1.

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. 1.





(c) Remove the gear shift fork shaft No. 1 from the intermediate plate.





(d) Remove the gear shift fork No. 1 from the reverse gear.





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





27. REMOVE REVERSE SHIFT FORK SHAFT





(a) Using a pin punch (5 mm) and a hammer, remove the shift fork set slotted spring pin from the gear shift fork No. 3.

(b) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the reverse shift fork shaft.





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

(c) Remove the gear shift fork No. 3 and reverse shift fork shaft from the intermediate plate.





(d) Using a magnetic finger, remove the shift interlock No. 1 roller from the intermediate plate.





(e) Using a magnetic finger, remove the reverse shift fork ball from the reverse shift fork.





28. REMOVE 5TH SHIFT ARM SHAFT





(a) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the 5th shift arm shaft.

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

(b) Remove the 5th shift arm shaft from the intermediate plate.





NOTICE:
Cover the hole with a shop rag to prevent the reverse shift fork ball from popping out.

(c) Using a magnetic finger, remove the reverse shift fork return compression spring from the reverse shift fork.





29. REMOVE REVERSE SHIFT FORK





(a) Remove the reverse shift fork together with the reverse shift arm from the intermediate plate.

(b) Using a screwdriver, remove the reverse shift arm end shaft ring and the reverse shift fork from the reverse shift arm.





30. REMOVE REVERSE SHIFT ARM BRACKET





(a) Remove the 2 bolts and reverse shift arm bracket from the intermediate plate.

31. REMOVE SPEEDOMETER DRIVE GEAR





(a) Using snap ring pliers, remove the snap ring.

(b) Remove the speedometer driver gear and ball.

(c) Using a magnetic finger, remove the steel ball.

(d) Using snap ring pliers, remove the snap ring.

32. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING





(a) Using 2 screwdrivers and a hammer, remove the output shaft bearing shaft snap ring from the output shaft.

33. REMOVE OUTPUT SHAFT REAR BEARING





(a) Using SST, remove the output shaft rear bearing and output shaft spacer from the output shaft.

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04051

09957-04010

09958-04011

34. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE





(a) Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

35. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.

Standard clearance:

0.015 to 0.068 mm (0.0059 to 0.0027 in.)

If the clearance is not within the specified values, replace the counter 5th gear bearing with a new one.

36. REMOVE COUNTER GEAR REAR SHAFT SNAP RING





(a) Using 2 screwdrivers and a hammer, remove the counter gear rear shaft snap ring from the counter gear.

37. REMOVE NO. 5 GEAR SPLINE PIECE





(a) Using SST, remove the gear spline piece No. 5 from the counter gear.

SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05021

09957-04010

38. REMOVE NO. 3 SYNCHRONIZER RING OUTER





(a) Remove the synchronizer ring outer No. 3 from the counter gear.

39. REMOVE COUNTER SHAFT 5TH GEAR





(a) Remove the counter shaft 5th gear and transmission hub sleeve No. 3 assembly from the counter gear.

40. REMOVE COUNTER 5TH GEAR BEARING





(a) Remove the counter 5th gear bearing from the counter 5th gear.

41. REMOVE NO. 3 TRANSMISSION HUB SLEEVE





(a) Using a snap ring expander, remove the snap ring.

(b) Remove the transmission hub sleeve No. 3, 2 synchromesh shifting keys No. 3 and 2 synchromesh shifting key springs No. 3 from the counter shaft 5th gear.





42. REMOVE 5TH GEAR THRUST WASHER





(a) Remove the 5th gear thrust washer from the counter gear.

43. REMOVE 5TH GEAR THRUST WASHER PIN





(a) Remove the 5th gear thrust washer pin from the counter gear.

44. REMOVE OUTPUT SHAFT REAR BEARING RETAINER





(a) Remove the 4 bolts and output shaft rear bearing retainer from the intermediate plate.

45. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY





(a) Pull out the reverse idler gear shaft to the rear side and remove the reverse idler gear from the intermediate plate.

46. REMOVE COUNTER SHAFT CENTER BEARING





(a) Using a snap ring expander, remove the snap ring.

(b) Using SST, remove the counter shaft center bearing from the intermediate plate.





SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04011

09957-04010

09958-04011

HINT
Remove the bearing while tapping the tip of the counter gear so that the counter gear assembly is not pushed forward into the side wall of the output shaft gear.

47. REMOVE COUNTER GEAR





(a) Remove the counter gear assembly from the intermediate plate.

48. REMOVE INPUT SHAFT ASSEMBLY





(a) Remove the input shaft assembly and synchronizer ring No. 2 from the output shaft.

NOTICE:
Do not drop the input shaft bearing and synchronizer ring No. 2.

49. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING





(a) Using a snap ring expander, remove the output shaft bearing shaft snap ring from the output shaft.

50. REMOVE OUTPUT SHAFT ASSEMBLY





(a) Using a plastic hammer, remove the output shaft assembly by tapping the intermediate plate.