MANUAL TRANSMISSION UNIT > REMOVAL

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1. Remove the filler plug and gasket from the transmission case.
   

1. Remove the drain plug and gasket from the transmission case.
   

1. Remove the release fork and release bearing from the clutch housing.
   

1. Remove the clip and then remove the release bearing from the release fork.
   

1. Remove the release fork support from the clutch housing.
   

1. Remove the release fork boot from the clutch housing.
   

1. Remove the 9 bolts.
   

2. Using a plastic-faced hammer, tap out the clutch housing from the transmission case.
   

1. Using SST, remove the back-up light switch and gasket from the transmission case.
   

   SST

   09817-16011  
   

1. Remove the 2 restrict pins from the transfer adapter.
   

1. Remove the 4 bolts.
   

2. Remove the control shift lever retainer.
   

3. Remove the oil deflector.
   

1. Remove the 4 bolts.
   

2. Remove the shift lever retainer from the transfer adapter.
   

3. Remove the select return spring from the shift lever retainer.
   

1. Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the shift lever housing.
   

2. Remove the shift and select lever shaft and shift lever housing from the transfer adapter.
   

1. Remove the 10 bolts.
   

2. Using a brass bar and hammer, tap out the transfer adapter from the transmission case.
   

1. Using a T40 ''torx'' socket wrench, remove the plug.
   

2. Using a 5 mm pin punch and hammer, tap out the restrict slotted pin.
   

3. Remove the restrict pin.
   

1. Using a screwdriver and hammer, tap out the oil seal from the transfer adapter.
   

1. Remove the 8 bolts.
   

2. Using a brass bar and hammer, tap out the retainer from the transmission case.
   

1. Fix the front bearing retainer in a vise.
   

2. Using SST, tap out the oil seal.
   

   SST

   09308-00010  
   

1. Using a snap ring expander, remove the snap ring from the transmission case.
   

1. Using a snap ring expander, remove the snap ring from the transmission case.
   

1. Using a brass bar and hammer, tap out the transmission case from the intermediate plate.
   

1. Remove the magnet from the intermediate plate.
   

1. Fix the intermediate plate in a vise between aluminum plates.
   

1. Using a T40 ''torx'' socket wrench, remove the spring seat from the intermediate plate.
   

2. Using a magnet hand, remove the compression spring and detent ball from the intermediate plate.
   

3. Using a T40 ''torx'' socket wrench, remove the 2 spring seats from the intermediate plate.
   

4. Using a magnet hand, remove the 2 compression springs and 2 detent balls from the intermediate plate.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 shift fork shaft.
   

   NOTICE:

   Use a cloth to prevent the snap ring from flying off.

2. Remove the bolt from the No. 2 shift fork.
   

3. Remove the No. 2 shift fork shaft from the intermediate plate.
   

4. Remove the No. 2 shift fork from the No. 2 transmission hub sleeve.
   

5. Using a magnet hand, remove the No. 1 shift interlock roller and shift interlock pin from the intermediate plate.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 1 shift fork shaft.
   

   NOTICE:

   Use a cloth to prevent the snap ring from flying off.

2. Remove the bolt from the No. 1 shift fork.
   

3. Remove the No. 1 shift fork shaft from the intermediate plate.
   

4. Remove the No. 1 shift fork from the reverse gear.
   

5. Using a magnet hand, remove the No. 1 shift interlock roller from the intermediate plate.
   

1. Using a 5 mm pin punch and hammer, tap out the shift fork set slotted pin from the No. 3 shift fork.
   

2. Using 2 screwdrivers and a hammer, tap out the snap ring from the shift fork shaft.
   

   NOTICE:

   Use a cloth to prevent the snap ring from flying off.

3. Using a magnet hand, remove the straight pin from the reverse shift fork.
   

4. Remove the No. 3 shift fork and No. 3 shift fork shaft from the intermediate plate.
   

5. Using a magnet hand, remove the No. 1 shift interlock roller from the intermediate plate.
   

1. Remove the reverse shift fork from the reverse shift arm.
   

1. Remove the torsion spring from the reverse shift arm bracket.
   

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

3. Using a screwdriver, pry out the snap ring from the reverse shift arm bracket.
   

4. Remove the reverse shift arm from the reverse shift arm bracket.
   

1. Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the output shaft.
   

1. Using SST, remove the 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)
   

1. Using a feeler gauge, measure the thrust clearance.
   

   Standard clearance:

   0.10 to 0.35 mm (0.0039 to 0.0138 in.)
   

   If the clearance is not as specified, replace the counter 5th gear.
   

1. Using a dial indicator, measure the radial clearance.
   

   Standard clearance:

   0.015 to 0.068 mm (0.0059 to 0.0027 in.)
   

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

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the counter gear.
   

1. Remove the No. 3 transmission hub sleeve from the counter 5th gear.
   

1. Using SST, remove the counter 5th gear together with the 2 No. 3 synchromesh shifting keys, 2 No. 3 synchromesh shifting key springs, No. 3 synchronizer ring and No. 5 gear spring piece from the counter gear.
   

   SST

   09950-40011   (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011)
   

1. Remove the No. 5 gear spring piece from the counter 5th gear.
   

1. Remove the synchronizer ring from the counter 5th gear.
   

1. Remove the bearing from the counter 5th gear.
   

1. Using a snap ring expander, remove the snap ring.
   

2. Remove the No. 3 synchromesh shifting key spring and 2 No. 3 synchromesh shifting keys from the counter 5th gear.
   

1. Remove the thrust washer from the counter gear.
   

1. Remove the thrust washer pin from the counter gear.
   

1. Remove the 4 bolts and bearing retainer from the intermediate plate.
   

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

1. Using a snap ring expander, remove the snap ring.
   

2. Using SST, remove the 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 does not hit the side wall of the output shaft gear by being pushed forward.

1. Remove the counter gear from the intermediate plate.
   

1. Remove the input shaft and No. 2 synchronizer ring from the output shaft.
   

   NOTICE:

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

1. Using a snap ring expander, remove the snap ring from the output shaft.
   

1. Using a plastic-faced hammer, remove the output shaft by tapping the intermediate plate.
   

1. Apply gear oil to the cone part of the No. 5 gear spline piece, and check that it does not turn in both directions while pushing the No. 3 synchronizer ring to the No. 5 gear spline piece.
   If it can turn, replace the No. 3 synchronizer ring.
   

2. Push the No. 3 synchronizer ring outer to the cone part of the No. 5 gear spline piece. Measure the clearance between the No. 3 synchronizer ring outer and No. 5 gear spline piece.
   

   Standard clearance:

   0.68 to 1.32 mm (0.0268 to 0.0519 in.)
   

   If the clearance is not as specified, replace the No. 3 synchronizer ring outer with a new one.
   

1. Check the sliding condition between the counter shaft 5th gear and No. 3 transmission hub sleeve.
   

2. Check the tip of the spline gear of the No. 3 transmission hub sleeve for wear.
   If there are any defects, replace the No. 3 transmission hub sleeve.
   

3. Using a vernier caliper, measure the No. 3 transmission hub sleeve groove and the thickness of the claw part of the No. 3 shift fork to calculate the clearance.
   

   Standard clearance:

   0.26 to 0.84 mm (0.0102 to 0.0331 in.)
   

   If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 shift fork with new ones.
   

1. Using a cylinder gauge, measure the inside diameter of the counter 5th gear.
   

   Standard inside diameter:

   38.015 to 38.040 mm (1.4967 to 1.4976 in.)
   

   Maximum inside diameter:

   38.040 mm (1.4976 in.)
   

   If the inside diameter is greater than the maximum, replace the counter shaft 5th gear with a new one.
   

1. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
   

   Standard inside diameter:

   24.040 to 24.061 mm (0.9465 to 0.9473 in.)
   

   Maximum inside diameter:

   24.061 mm (0.9473 in.)
   

   If the inside diameter is greater than the maximum, replace the reverse idler gear with a new one.
   

2. Using a micrometer, measure the diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.
   

   Standard diameter:

   23.979 to 24.000 mm (0.9441 to 0.9449 in.)
   

   Minimum diameter:

   23.979 mm (0.9441 in.)
   

   If the diameter is less than the minimum, replace the reverse idler gear shaft.
   

3. Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and reverse shift arm.
   

   Standard clearance:

   0.05 to 0.35 mm (0.0020 to 0.0138 in.)
   

   If the clearance is not as specified, replace the reverse idler gear and reverse shift arm.
   

1. Install the reverse idler gear on the reverse idler gear shaft, and clamp it to a vise.
   

2. Using a dial indicator, measure the radical clearance.
   

   Standard clearance:

   0.040 to 0.082 mm (0.0016 to 0.0032 in.)
   

   If the clearance is not as specified, replace the reverse idler gear.