Manual Transmission Disassembly

Manual Transmission Disassembly

Exploded View - Clutch Housing





Exploded View - Transmission Housing





NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Remove the release bearing and the release fork.

2. Remove the strainer cover (A), the O-ring (B), the strainer set spring (C), and the oil pump strainer (D).






3. Remove transmission hanger A.





4. Remove the reverse lockout solenoid (B), the select lock pin (C), the select lock pin spring (D), and the back-up light switch (E).

5. Remove the detent bolts (A), the 22.0 mm detent ball spring (B), the 26.1 mm detent ball spring (C), the 27.4 mm detent ball springs (D), the steel balls (E), the filler plug (F), and the 20 mm sealing washer (G).






6. Remove the detent bolts (A), the 22.0 mm detent ball spring (B), the 27.4 mm detent ball spring (C), the steel balls (D), the input shaft (mainshaft) speed sensor (E), the output shaft (countershaft) speed sensor (F), and the O-rings (G).






7. Remove the fluid check bolt (A), the 6 mm sealing washer (B), the drain plug (C), and the 20 mm sealing washer (D).






8. Loosen the 10 mm flange bolts in a crisscross pattern in several steps, then remove them with the clutch line bracket (A) and transmission hanger B.






9. Remove the transmission case cap (A) and the O-ring (B).





10. While expanding the 75 mm snap ring (C) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (D). Release the snap ring pliers, and remove the transmission housing and the three 14 x 20 mm dowel pins (E).

11. Remove oil guide pipe A, the oil guide pipe (B), and the magnet (C).






12. Remove the 8 x 50 mm pin (A) and the reverse shift lever (B).






13. Remove the 25 mm thrust washers (A), the 25 mm thrust needle bearings (B), the reverse idler gear shaft assembly (C), the 36 mm spring washer (D), and the reverse shift fork (E) as an assembly.






14. Remove the 8 x 50 mm pin (A), the select return spring (B), the shift piece shaft (C), the shift piece (D), and the interlock (E).






15. Remove the 5 x 22 mm spring pin (A), the 3 x 22 mm spring pin (B), the select arm (C), the select lever (D), and the 14 x 20 x 4 mm dust seal (E).






16. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

NOTE: Do not apply tape thick to damage the oil seal.





17. Remove the 64 mm spring washer (E).

18. Remove the oil pump shaft (A) and the differential assembly (B).






19. Remove the transfer output shaft assembly (A).






20. Remove the oil guide plate (A).






21. Remove the oil pump plate (A), the oil pump inner rotor (B), and the oil pump outer rotor (C).






22. Remove the 87 mm shim (A) from the transmission housing (B).






23. Remove the 8 mm special bolt (A), the 8 mm spring washer (B), the shift arm (C), the change lever (D), and the 16 x 23 x 5 mm dust seal (E).





24. Remove the breather cap (F).