Disassembly

Disassembly

1. Remove the seal bolt with the rolling plunger and guide spring.

NOTE:
The bracket holding the back up lamp switch connector is installed with the seal plug.




2. Remove the back up lamp switch with the gasket.




3. After releasing the caulking, remove the flange assembly by removing the locking nut(35mm).

CAUTION:
Be careful not to damage the oil seal inside of the dust cover.




4. Remove the hinge bolts (2ea) for retaining the reverse shift fork on both sides of the extension housing.








5. Remove the poppet ball bearing assembly.




6. Remove the inter lock bolt and guide bolt.

CAUTION:
Be sure not to switch the bolts, because two bolts are simillar but not the same.




7. Remove the mounting bolts(12ea) of the extension housing and remove the extension housing by using a rubber hammer.








8. Remove the oil seals(2ea) from the extension housing.




9. Remove the C.S.C assembly by removing the bolts(3ea).

NOTE:
In advance remove the rubber from the transmission case.




10. Remove the front bearing retainer assembly by removing the bolts(8ea).




11. Remove the spacer from the front bearing retainer assembly.




12. Remove the snap ring from the main drive pinion assembly.




13. Remove the transmission case assembly by using a rubber hammer.

CAUTION:
Be careful not to drop and damage to the pinion drive assembly.




14. Remove the oil guide.




15. Remove the stopper lever by pulling out the clip and pin.




16. Remove the reverse shift fork.




17. Remove the reverse shift rug.




18. Remove the reverse idler gear assembly.




19. Remove the 5&6th shift lever assembly by removing the bolts(2ea).




20. After pulling out the spring pins each from 1&2nd and 3&4th forks with hammer and chisel, remove the shift rails.

NOTE:
Remove the nut in order to remove the 5&6th shift rail.




21. After releasing the caulking, remvoe the locking nut from the cout shaft assembly.




22. Remove the count shaft reverse gear.

CAUTION:
Place the chamfer inside of the gear toward the engine side.




23. Remove the ball bearing, reverse synchronizer hub&sleeve assembly, synchronizer ring, reverse gear assembly altogether by using a puller.




24. Remove the neelde roller bearing.




25. Remove the 3rd speed gear of main shaft and reverse gear sleeve by using a puller.




26. Remove the 3rd gear assembly, needle roller bearing, and synchronizer ring assembly.




27. Remove the 3&4th shift fork.




28. After removing the synchronizer keys, remove the 3&4th synchronizer hub&sleeve assembly, synchronizer ring and 4th gear assembly altogether by using a puller.




29. Remove the needle roller bearing.




30. Remove the main shaft 4th gear and spacer.




31. Remove the bearing retainer by removing the bolts(8ea) with TORX wrench.




32. Remove the oil guide by removing the bolts(2ea).




33. Remove the snap rings each from the main drive shaft and the count shaft.








34. Disassembly the main drive shaft and the count shaft from the intermediate plate.