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
1.
Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).
2.
Remove the 20 mm bolt (A) and the 20 mm sealing washer (B).
3.
Remove the change lever assembly (A) and the 8 x 10 mm dowel pins (B).
4.
Remove the back-up light switch (A) and the 18 mm sealing washer (B).
5.
Remove the filler plug (A) and the 20 mm sealing washer (B).
6.
Remove the drain plug (C) and the 14 mm sealing washer (D).
7.
Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).
8.
Remove the 32 mm sealing cap (A).
9.
Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them with transmission hanger (A).
10.
While expanding the 69 mm snap ring (A) on the countershaft ball bearing with the snap ring pliers, lift the transmission housing (B). Release the snap ring pliers, and remove the transmission housing and the 14 x 20 mm dowel pins (C).

2. Reverse Shift Fork - Remove

3. Reverse Idler Gear and Reverse Idler Gear Shaft - Remove

4. 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 26 mm washer (D) and the 36 mm spring washer (E).

5. Differential Assembly and Magnet - Remove

6. Oil Guide Plate M, 52 x 62 mm Shim, and Oil Gutter Plate - Remove


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
NOTE: Clean the magnet and the clutch housing.


2. Mainshaft, Countershaft, and Shift Fork Assembly - Install
1.
Install the 36 mm spring washer (A) and the 26 mm washer (B) over the ball bearing (C).
NOTE: Be sure to install the spring washer in the direction shown.
2.
Apply a thin layer of tape to the mainshaft splines (D) 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 (E) with the shift fork assembly (F) as an assembly.

3. Reverse Idler Gear and Reverse Idler Gear Shaft - Install

4. Reverse Shift Fork - Install

5. Oil Guide Plate M, 52 x 62 mm Shim, and Oil Gutter Plate - Install

2.
Install oil guide plate M and the 52 x 62 mm shim.
3.
Install the oil gutter plate (B).

6. 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.
Place the transmission housing on the clutch housing, making sure to line up the shafts.
NOTE: When installing the transmission housing to the clutch housing, push the 69 mm snap ring (B) towards the direction pointed by the arrow shown in the picture to make sure to place the 69 mm snap ring properly without holding it between the transmission housing and the countershaft ball bearing.
5.
While expanding the 69 mm snap ring (A) 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 until it bottoms out and the snap ring snaps in place in the snap ring groove of the countershaft ball bearing.
6.
Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.
Dimension as installed:
 
3.3?6.5 mm (0.130?0.256 in)
7.
Install the 8 mm flange bolts finger-tight with the transmission hanger (A).
8.
Tighten the 8 mm flange bolts in the numbered sequence shown.
Specified Torque:
27 N·m
(2.8 kgf·m, 20 lbf·ft)
9.
Clean any dirt and oil from the sealing surface of the 32 mm sealing cap (A) and the transmission housing.
10.
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.
11.
Install the output shaft (countershaft) speed sensor (A), the plain washer (B), and a new O-ring (C).
12.
Install the filler plug (A) with a new 20 mm sealing washer (B) finger-tight.
13.
Install the drain plug (C) with a new 14 mm sealing washer (D).
14.
Install the back-up light switch (A) with a new 18 mm sealing washer (B).
15.
Clean any dirt and oil from the sealing surface of the change lever assembly and the transmission housing.
16.
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.
17.
Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).
18.
Turn the breather cap mark (C) toward the front side of the vehicle.
19.
Install the 20 mm bolt (A) with a new 20 mm sealing washer (B).
20.
Install the steel balls (A), the detent ball springs (B), and the detent bolts (C) with new 12 mm sealing washers (D).
21.
Check that the transmission shifts into all gears smoothly.