Manual Transmission Disassembly and Reassembly (K20C1 (M/T))

Manual Transmission Disassembly and Reassembly

Special Tools Required

Image	Description/Tool Number
	Weight, Remover 07741-0010201
	Bearing Driver Attachment, 52 x 55 mm 07746-0010400
	Bearing Driver Attachment, 72 x 75 mm 07746-0010600
	Bearing Driver Attachment, 24 x 26 mm 07746-0010700
	Driver Handle, 15 x 135L 07749-0010000
	Bearing Remover Shaft 07JAC-PH80200
	Oil Seal Driver Attachment, 60 mm 07LAD-SM40100
	Snap Ring Pliers 07LGC-0010100
	Oil Seal Driver Attachment 07NAD-P200100
	Bearing Driver Attachment, 78 x 80 mm 07NAD-PX40100
	Adjustable Bearing Puller, 45?75 mm 07YAC-0010102

NOTE:

Where icon is shown, click for further information.

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

	Detailed information, notes, and precautions
	Replace

	Detailed information, notes, and precautions
	Replace

	Detailed information, notes, and precautions
	Replace

1.	Release Bearing - Remove

2.	Reverse Lockout Solenoid - Remove

3.	Oil Pump Strainer - Remove

NOTE: Clean the strainer anytime the transmission is disassembled.

4.	Back-Up Light Switch - Remove

5.	Neutral Position Sensor - Remove

6.	Input Shaft (Mainshaft) Speed Sensor - Remove

7.	Output Shaft (Countershaft) Speed Sensor - Remove

8.	Detent Bolt - Remove

9.	23.6 mm Detent Ball Spring - Remove

10.	Steel Ball - Remove

11.	Detent Bolt - Remove

12.	26.0 mm Detent Ball Spring - Remove

13.	Steel Ball - Remove

14.	Detent Bolt - Remove

15.	27.4 mm Detent Ball Spring - Remove

16.	Steel Ball - Remove

17.	Filler Plug - Remove

18.	Oil Check Bolt - Remove

19.	Drain Plug - Remove

20.	Transmission Hanger D - Remove

21.	Breather Cap - Remove

22.	Transmission Case Cap - Remove

23.	10 mm Flange Bolt - Loosen

24.	Transmission Hanger B - Remove

25.	Clutch Pipe Bracket - Remove

26.	Transmission Housing - Remove

Expand the 75 mm snap ring (A) on the countershaft ball bearing, and remove it from the groove using the snap ring pliers.

Remove the transmission housing (B) and the 14 x 20 mm dowel pins (C).

27.	87 mm Shim - Remove

28.	8 mm Special Bolt - Remove

29.	Spring Washer - Remove

30.	Shift Arm - Remove

31.	Change Lever - Remove

32.	16 x 23 x 5 mm Dust Seal - Remove

33.	75 mm Snap Ring - Remove

34.	42 x 58 x 12.5 mm Oil Seal - Remove (Transmission Housing Side)

35.	50 x 81 x 18 mm Bearing Outer Race, 46 x 81 x 1 mm Spacer and 81 mm Shim - Remove (Transmission Housing Side)

Remove the 50 x 81 x 18 mm bearing outer race (A), the 46 x 81 x 1 mm spacer (B), and the 81 mm shim (C) by heating the transmission housing to about 212 °F (100 °C) with a heat gun.

36.	Oil Guide Pipe A - Remove

37.	Oil Guide Pipe B - Remove

38.	Magnet - Remove

NOTE: Clean the magnet anytime the transmission is disassembled.

39.	8 x 50 mm Pin - Remove

40.	Reverse Shift Lever - Remove

41.	Reverse Idler Gear Shaft - Remove

42.	Thrust Washer - Remove

43.	Thrust Needle Bearing - Remove

44.	Reverse Driven Gear - Remove

45.	Reverse Synchro Sleeve - Remove

46.	Reverse Shift Fork - Remove

47.	Synchro Spring - Remove

48.	Reverse Synchro Ring - Remove

49.	Needle Bearing - Remove

50.	Thrust Needle Bearing - Remove

51.	Thrust Washer - Remove

52.	Thrust Needle Bearing - Remove

53.	Needle Bearing - Remove

54.	Reverse Drive Gear - Remove

55.	Thrust Needle Bearing - Remove

56.	Thrust Washer - Remove

57.	Spring Washer - Remove

58.	8 x 50 mm Pin - Remove

59.	Shift Piece Shaft - Remove

60.	Shift Piece - Remove

61.	Interlock - Remove

62.	Return Spring - Remove

63.	5 x 22 mm Spring Pin and 3 x 22 mm Spring Pin - Remove

Remove the 5 x 22 mm spring pin and the 3 x 22 mm spring pin together as shown.

64.	Select Lever and Select Arm - Remove

65.	14 x 20 x 4 mm Dust Seal - Remove

66.	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).

67.	Spring Washer - Remove

68.	28 x 43 x 7 mm Oil Seal - Remove

69.	Oil Pump Shaft - Remove

70.	Differential Assembly - Remove

71.	Oil Gutter Plate - Remove

72.	Bearing Set Plate - Remove

73.	Countershaft Bearing - Remove (Clutch Housing Side)

Remove the countershaft bearing using the 45?75 mm adjustable bearing puller, the bearing remover shaft, and the remover weight.

74.	Oil Pump Plate - Remove

75.	Oil Pump Inner Rotor - Remove

76.	Oil Pump Outer Rotor - Remove

77.	16.1 mm Detent Ball Spring - Remove

78.	Steel Ball - Remove

79.	37 x 56 x 8 mm Oil Seal - Remove (Clutch Housing Side)

80.	45 x 80 x 21 mm Bearing Outer Race and 46 x 80 x 1 mm Spacer - Remove (Clutch Housing Side)

Remove the 45 x 80 x 21 mm bearing outer race (A) and the 46 x 80 x 1 mm spacer (B) by heating the clutch housing to about 212 °F (100 °C) with a heat gun.

NOTE:

Where icon is shown, click for further information.

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

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

When applying liquid gasket, clean any dirt and oil off from the sealing surfaces.

If any of the items listed were replaced, do the differential carrier bearing preload adjustment before reassembling the transmission.

Transmission housing

Clutch housing

Differential carrier

Spacer

Carrier bearing and outer race

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace

1.	46 x 80 x 1 mm Spacer - Install

2.	45 x 80 x 21 mm Bearing Outer Race - Install (Clutch Housing Side)

Install the 45 x 80 x 21 mm bearing outer race using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment.

3.	37 x 56 x 8 mm Oil Seal - Install (Clutch Housing Side)

Install the 37 x 56 x 8 mm oil seal flush with the clutch housing using the 15 x 135L driver handle and the oil seal driver attachment.

4.	Steel Ball - Install

5.	16.1 mm Detent Ball Spring - Install

6.	Oil Pump Outer Rotor - Install

7.	Oil Pump Inner Rotor - Install

8.	Oil Pump Plate - Install

9.	Countershaft Bearing - Install (Clutch Housing Side)

Install the countershaft bearing using the 15 x 135L driver handle and the 72 x 75 mm bearing driver attachment.

10.	Bearing Set Plate - Install

11.	Oil Gutter Plate - Install

Install the oil gutter plate (A) press-fit to the clutch housing surface (B).

12.	Differential Assembly - Install

13.	Oil Pump Shaft - Install

Install the oil pump shaft (A) while aligning the notch cut (B) of the oil pump shaft with the notch cut of the oil pump inner rotor (C) as shown.

14.	28 x 43 x 7 mm Oil Seal - Install

Install the 28 x 43 x 7 mm oil seal (A) flush with the clutch housing (B) as shown using the 15 x 135L driver handle and the 52 x 55 mm bearing driver attachment.

15.	Spring Washer - Install

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

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

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.

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

17.	14 x 20 x 4 mm Dust Seal - Install

Install the 14 x 20 x 4 mm dust seal flush with the clutch housing surface using the 15 x 135L driver handle and the 24 x 26 mm bearing driver attachment.

18.	Select Lever and Select Arm - Install

Install the select lever (A) and the select arm (B) as shown.

19.	5 x 22 mm Spring Pin and 3 x 22 mm Spring Pin - Install

Install the 5 x 22 mm spring pin (A) and the 3 x 22 mm spring pin (B) together as shown.

NOTE: Make sure the seams (C) of the 5 x 22 mm and the3 x 22 mm spring pin are opposite side.

20.	Return Spring and 8 x 50 mm Pin - Install

Install the select return spring (A) and the 8 x 50 mm pin (B) as shown.

21.	Interlock - Install

Install the interlock (A).

NOTE: Align the interlock with the select arm (B), the select return spring (C), and the shift fork assembly (D).

22.	Shift Piece and Shift Piece Shaft - Install

Install the shift piece (A) and the shift piece shaft (B).

NOTE: Align the shift piece with the shift fork assembly (C).

23.	Reverse Idler Gear Shaft Assembly and Reverse Shift Fork - Install

Install these parts in the following order:

-1.

Reverse drive gear (A)

-2.

Reverse idler gear shaft (B)

-3.

Needle bearing (C)

-4.

Thrust needle bearing (D)

-5.

Thrust washer (E)

-6.

Thrust needle bearing (F)

-7.

Needle bearing (G)

Install the reverse synchro sleeve (A) in the direction shown by aligning the slots of the reverse synchro sleeve and the reverse driven gear (B).

NOTE: Make sure to align the slots in the reverse driven gear as shown.

Set the synchro spring (A) to the synchro ring (B) and install to the reverse driven gear (C) as shown.

Install the reverse driven gear set (A) in the reverse driven gear set (B).

Assemble the thrust needle bearings (A), the thrust washers (B), the spring washer (C), the reverse idler gear shaft assembly (D), and the reverse shift fork (E).

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.

24.	Reverse Shift Lever and 8 x 50 mm Pin - Install

While aligning the opening (A) with the reverse shift fork (B), install the reverse shift lever (C) and secure it with the 8 x 50 mm pin (D).

25.	Magnet - Install

26.	81 mm Shim - Select

27.	81 mm Shim - Install

28.	46 x 81 x 1 mm Spacer - Install

29.	50 x 81 x 18 mm Bearing Outer Race - Install (Transmission Housing Side)

Install the 50 x 81 x 18 mm bearing outer race using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment.

30.	42 x 58 x 12.5 mm Oil Seal - Install (Transmission Housing Side)

Install the 42 x 58 x 12.5 mm oil seal flush with the transmission housing using the 15 x 135L driver handle and the 60 mm oil seal driver attachment.

31.	75 mm Snap Ring - Install

NOTE: Make sure the snap ring is firmly installed in the groove.

32.	16 x 23 x 5 mm Dust Seal - Install

Install the 16 x 23 x 5 mm dust seal flush with the transmission housing surface using the 15 x 135L driver handle and the 24 x 26 mm bearing driver attachment.

33.	Change Lever - Install

34.	Shift Arm - Install

35.	Spring Washer - Install

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

36.	8 mm Special Bolt - Install

37.	87 mm Shim - Select

38.	87 mm Shim - Install

39.	Oil Guide Pipe B - Install

Install oil guide pipe B while aligning the tip (A) with the hole (C) in the clutch housing.

40.	Oil Guide Pipe A - Install

NOTE: Install oil guide pipe A into the countershaft until it bottom of the clutch housing.

41.	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 08718-0003, 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 too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

Wait at least 30 minutes before filling MTF.

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

Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).

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.

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)

Check the operation of the change lever and the select lever.

42.	Clutch Pipe Bracket - Loosely Install

43.	Transmission Hanger B - Loosely Install

44.	10 mm Flange Bolt - Tighten

NOTE: Install the 10 mm flange bolts with transmission hanger B and the clutch pipe bracket in a crisscross pattern in several steps.

45.	Transmission Case Cap - Install

46.	Breather Cap - Install

47.	Transmission Hanger D - Install

48.	Drain Plug - Install

49.	Oil Check Bolt - Install

50.	Filler Plug Bolt - Install

51.	Steel Ball - Install

52.	27.4 mm Detent Ball Spring - Install

53.	Detent Bolt - Install

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

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

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

Wait at least 30 minutes before filling MTF.

54.	Steel Ball - Install

55.	26.0 mm Detent Ball Spring - Install

56.	Detent Bolt - Install

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

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolts. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

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

Wait at least 30 minutes before filling MTF.

57.	Steel Ball - Install

58.	23.6 mm Detent Ball Spring - Install

59.	Detent Bolt - Install

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

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

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

Wait at least 30 minutes before filling MTF.

60.	Output Shaft (Countershaft) Speed Sensor - Install

61.	Input Shaft (Mainshaft) Speed Sensor - Install

62.	Neutral Position Sensor - Install

63.	Back-Up Light Switch - Install

64.	Oil Pump Strainer - Install

65.	Reverse Lockout Solenoid - Install

66.	Release Bearing - Install