Manual Transmission Disassembly and Reassembly
Special Tools Required
Image Description/Tool Number
310230.png 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

2.
Remove the strainer cover (A), the O-ring (B), the strainer set spring (C), and the oil pump strainer (D).
3.
Remove the reverse lockout solenoid (A), the select lock pin (B), and the select lock pin spring (C).
4.
Remove the back-up light switch (D).
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), and the steel balls (E).
6.
Remove the filler plug (F) and the 20 mm sealing washer (G).
7.
Remove the detent bolts (A), the 22.0 mm detent ball spring (B), the 27.4 mm detent ball spring (C), and the steel balls (D).
8.
Remove the input shaft (mainshaft) speed sensor (E) and the O-ring (F).
9.
Remove the output shaft (countershaft) speed sensor (G) and the O-ring (H).
10.
Remove the oil check bolt (A) and the 6 mm sealing washer (B).
11.
Remove the drain plug (C) and the 14 mm sealing washer (D).
12.
Remove transmission hanger A, transmission hanger B, and the clutch line bracket (C). Loosen the 10 mm flange bolts in a crisscross pattern in several steps, then remove them.
13.
Remove the transmission case cap (A) and the O-ring (B).
14.
Expand the 75 mm snap ring (C) on the countershaft ball bearing, and remove it from the groove using the snap ring pliers.
15.
Remove the transmission housing (D) and the 14 x 20 mm dowel pins (E).

2. Oil Guide Pipe A, Oil Guide Pipe B, and Magnet - Remove
1.
Remove oil guide pipe A.
2.
Remove the oil guide pipe (B).
3.
Remove the magnet (C).

3. Reverse Shift Lever - Remove
Remove the reverse shift lever (A) and the 8 x 50 mm pin (B).


4. Reverse Idler Gear Shaft Assembly - Remove
Remove the 20 mm thrust washers (A), the 20 mm thrust needle bearings (B), the reverse idler gear shaft assembly (C), the 33 mm spring washer (D), and the reverse shift fork (E) as an assembly.


5. Select Lever - Remove
1.
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).
2.
Remove the 5 x 22 mm, 3 x 22 mm spring pins (A), the select arm (B), the 14 x 20 x 4 mm dust seal (C), and the select lever (D).

6. Mainshaft, Countershaft and Shift Fork Assembly - Remove
1.
Apply a thin layer of tape to the mainshaft splines to protect the seal.
NOTE: Do not apply too much tape as it will damage the oil seal.
2.
Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C).
3.
Remove the 64 mm spring washer (D).

7. Differential Assembly and Oil Pump Shaft - Remove
1.
Remove the differential assembly (A).
2.
Remove the oil pump shaft (B).

8. Oil Guide Plate - Remove
Remove the oil guide plate (A).


9. Oil Pump - Remove
Remove the oil pump plate (A), the oil pump inner rotor (B), and the oil pump outer rotor (C).


10. 82 mm Shim - Remove
Remove the 82 mm shim (A).


11. Change Lever - Remove
1.
Remove the 8 mm special bolt (A), the 8 mm spring washer (B), the shift arm (C), and the change lever (D).
2.
Remove the 16 x 23 x 5 mm dust seal (E).


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. Change Lever - Install
1.
Transmission housing
Clutch housing
Differential carrier
Spacer
Carrier bearing and outer race
2.
Press a new 16 x 23 x 5 mm dust seal (A) flush with the transmission housing surface.
3.
Install the change lever (B), the shift arm (C), the 8 mm spring washer (D), and the 8 mm special bolt (E).
NOTE: Be sure to install the spring washer in the direction shown.

3. Oil Pump - Install
Install the oil pump outer rotor (A), the oil pump inner rotor (B), and the oil pump plate (C).


4. Oil Guide Plate - Install
Install the oil guide plate (A).


5. Differential Assembly and Oil Pump Shaft - Install
1.
Install the differential assembly (A).
2.
Install the oil pump shaft (B).

6. Mainshaft, Countershaft and Shift Fork Assembly - Install
1.
Install the 64 mm spring washer (A).
NOTE: Be sure to install the spring washer in the direction shown.
2.
Apply a thin layer of tape to the mainshaft splines (B) to protect the seal.
NOTE: Do not apply too much tape as it will damage the oil seal.
3.
Install the mainshaft and the countershaft (C) with the shift fork assembly (D) as an assembly.

7. Select Lever - Install
1.
Press a new 14 x 20 x 4 mm dust seal (A) flush with the clutch housing surface.
2.
Install the select lever (B), the select arm (C), a new 5 x 22 mm spring pin (D), and a new 3 x 22 mm spring pin (E).
NOTE: Make the seams (F) of the 5 x 22 mm and 3 x 22 mm spring pin are opposite side.
3.
Apply MTF to the interlock (A).
4.
Set the select return spring (B), the 8 x 50 mm pin (C), and the interlock as shown.
5.
Install the shift piece (A) and the shift piece shaft (B).

8. Reverse Idler Gear Shaft Assembly - Install
1.
Assemble the 20 mm thrust needle bearings (A), the 20 mm thrust washers (B), the reverse idler gear shaft assembly (C), and the reverse shift fork (D).
2.
Install the 33 mm spring washer (E) to the reverse idler gear shaft assembly.
NOTE: Be sure to install the spring washer in the direction shown.
3.
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.

9. Reverse Shift Lever - Install
Install the reverse shift lever (A) and the 8 x 50 mm pin (B).


10. Oil Guide Pipe A, Oil Guide Pipe B, and Magnet - Install
1.
Install oil guide pipe A.
2.
Install the oil guide pipe (B).
3.
Install the magnet (C).
NOTE: Clean the magnet anytime the transmission is disassembled.
4.
Check the length of oil guide pipe A as shown.

11. Transmission Housing - Install
1.
Clean any dirt and oil from the sealing surface of the transmission housing and the clutch housing.
2.
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.
3.
Install the 14 x 20 mm dowel pins (A).
4.
Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
5.
While expanding the 75 mm snap ring (E) 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 pliers, and push down the housing unit it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.
6.
Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension as installed:
 
1.67?9.42 mm (0.0657?0.3709 in)
7.
Install a new O-ring (F) and the transmission case cap (G).
NOTE: Check the operation of the change lever and the select lever.
8.
Install the 10 mm flange bolts finger-tight with transmission hanger B and the clutch line bracket (C).
9.
Install transmission hanger A.
10.
Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
Specified Torque:
 
44 N·m (4.5 kgf·m, 32 lbf·ft)
11.
Install a new 6 mm sealing washer (A) and the oil check bolt (B) by finger-tight.
12.
Install the drain plug (C) and a new 14 mm sealing washer (D).
13.
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.
14.
Install the steel balls (B), the 22.0 mm detent ball spring (C), the 27.4 mm detent ball spring (D), and the detent bolts.
15.
Install the input shaft (mainshaft) speed sensor (E) and new O-ring (F).
16.
Install the output shaft (countershaft) speed sensor (G) and new O-ring (H).
17.
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.
18.
Install the steel balls (B), the 22.0 mm detent ball spring (C), the 26.1 mm detent ball spring (D), the 27.4 mm detent ball springs (E), and the detent bolts.
19.
Install a new 20 mm sealing washer (F) and the filler plug (G) by finger-tight.
20.
Clean any dirt and oil from the sealing surface of the reverse lockout solenoid and the transmission housing.
21.
Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the transmission housing mating surface of the reverse lockout solenoid. 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 select lock pin spring (A), the select lock pin (B), and the reverse lockout solenoid (C).
NOTE:
Apply MTF to the select lock pin.
Check the operation of the select lock pin.
23.
Clean any dirt and oil from the sealing surface of the back-up light switch (D) and the transmission housing.
24.
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.
25.
Install the oil pump strainer (A), the strainer set spring (B), and the strainer cover (C) with a new O-ring (D).
NOTE: Clean the strainer anytime the transmission is disassembled.