Manual Transmission Disassembly and Reassembly (L4: M/T)

Manual Transmission Disassembly and Reassembly

Special Tools Required

Image	Description/Tool Number
	Snap Ring Pliers 07LGC-0010100

1.	Clutch Housing - Exploded View

Exploded View - Clutch Housing

2.	Transmission Housing - Exploded View

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.	Transmission Housing - Remove

Remove the detent bolts (A), the 26.0 mm detent ball spring (B), the 23.4 mm detent ball spring (C), and the steel balls (D).

Remove the change lever assembly (A) and the 8 x 10 mm dowel pins (B).

Remove the detent bolts (A), the 26.0 mm detent ball springs (B), and the steel balls (C).

Remove the filler plug (D).

Remove the back-up light switch (A).

Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

Remove the detent bolt (A), the 26.0 mm detent ball spring (B), and the steel ball (C).

Remove the oil check bolt (D) and the 6 mm sealing washer (E).

Remove the 8 mm flange bolt (A) and the 8 mm packing (B).

10.

Remove the drain plug (A) and the 20 mm sealing washer (B).

11.

Remove the clutch line bracket (A). Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them.

12.

Remove the 32 mm sealing cap (A).

13.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing with the snap ring pliers, lift the transmission housing (C). Release the snap ring pliers, and remove the transmission housing and the 14 x 20 mm dowel pins (D).

2.	Oil Guide Plate C - Remove

While expanding the 72 mm snap ring (A) using the snap ring pliers, remove oil guide plate C.

3.	Oil Guide Plate M, 72 mm Shim, and Oil Gutter Plate A - Remove

Remove oil guide plate M and the 72 mm shim (B).

Remove oil gutter plate A.

4.	Oil Gutter Plate B - Remove

Remove oil gutter plate B.

5.	Reverse Shift Holder - Remove

Remove the reverse shift holder (A).

6.	Baffle Plate - Remove

Remove the baffle plate (A).

7.	Reverse Idler Gear Shaft Assembly - Remove

Remove the reverse idler gear shaft assembly (A), the 33 mm spring washer (B), and the reverse shift fork (C) as an assembly.

8.	Shift Piece - Remove

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

9.	Mainshaft, Countershaft and Shift Fork Assembly - Remove

Apply a thin layer of tape to the mainshaft splines to protect the oil seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C).

Remove the 64 mm spring washer (D).

10.	Differential Assembly and Magnet - Remove

Remove the differential assembly (A).

Remove the magnet (B).

NOTE:

Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

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

1.	Differential Assembly and Magnet - Install

Install the differential assembly (A).

Install the magnet (B).

NOTE: Clean the magnet anytime the transmission is disassembled.

2.	Mainshaft, Countershaft, and Shift Fork Assembly - Install

Install the 64 mm spring washer (A).

NOTE: Be sure to install the spring washer in the direction shown.

Apply a thin layer of tape to the mainshaft splines (B) to protect the oil seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

Install the mainshaft and the countershaft (C) with the shift fork assembly (D) as an assembly.

3.	Shift Piece - Install

Set the shift piece shaft (A), the shift piece (B), the interlock (C) the select return spring (D), the shift piece collar (E), and the 8 x 50 mm pin (F) as shown.

4.	Reverse Idler Gear Shaft Assembly - Install

Assemble the reverse idler gear shaft assembly (A) and the reverse shift fork (B).

Install the 33 mm spring washer (C).

NOTE: Be sure to install the spring washer in the direction shown.

Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing.

Align the mark (A) on the clutch housing with the reverse gear holder hole (B).

5.	Baffle Plate - Install

Install the baffle plate (A).

6.	Reverse Shift Holder - Install

Install the reverse shift holder (A).

7.	Oil Gutter Plate B - Install

Install oil gutter plate B.

8.	Oil Guide Plate M, 72 mm Shim, and Oil Gutter Plate A - Install

Select the proper size 72 mm shim (B) according to the measurements made during the Mainshaft Thrust Clearance Adjustment.

Install oil guide plate M and the 72 mm shim.

Install oil gutter plate A.

9.	Oil Guide Plate C - Install

While expanding the 72 mm snap ring (A) using the snap ring pliers, install oil guide plate C.

10.	Transmission Housing - Install

Clean any dirt and oil from the sealing surface of the transmission housing and the clutch housing.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

Install the 14 x 20 mm dowel pins (A).

Place the transmission housing on the clutch housing, making sure to line up the shafts.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing using the snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the snap ring pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.

Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension

as installed:

3.3?6.0 mm(0.130?0.236 in)

Make sure oil guide plate C is positioned on the transmission housing as shown.

Clean any dirt and oil from the sealing surface of the 32 mm sealing cap (A) and the transmission housing.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

10.

Install the 8 mm flange bolts finger-tight with the clutch line bracket (A).

11.

Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

Specified Torque:

27 N·m (2.8 kgf·m, 20 lbf·ft)

12.

Install the drain plug (A) with a new 20 mm sealing washer (B).

13.

Install the 8 mm flange bolt (A) with a new 8 mm packing (B).

14.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the thread of the detent bolt (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

15.

Install the steel ball (B), the 26.0 mm detent ball spring (C), and the detent bolt.

16.

Install the oil check bolt (D) with a new 6 mm sealing washer (E) finger-tight.

17.

Apply MTF to a new O-ring (A).

18.

Install the output shaft (countershaft) speed sensor (B), the plain washer (C), and the O-ring.

19.

Clean any dirt and oil from the sealing surface of the back-up light switch (A) and the transmission housing.

20.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the threads of the back-up light switch. Install the back-up light switch within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

21.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the thread of the detent bolts (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

22.

Install the steel balls (B), the 26.0 mm detent ball springs (C), and the detent bolts.

23.

Install the filler plug (D) finger-tight.

24.

Clean any dirt and oil from the sealing surface of the change lever assembly and the transmission housing.

25.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

26.

Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).

27.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the thread of the detent bolts (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

28.

Install the steel balls (B), the 26.0 mm detent ball spring (C), the 23.4 mm detent ball spring (D), and the detent bolts.

29.

Check the position of the breather cap mark (A) as shown.

30.

Check that the transmission shifts into all gears smoothly.