Disassembly

TRANSMISSION ASSEMBLY

Disassembly


CASE AND EXTENSION

1.Remove drain plug and gasket from transmission case and then drain gear oil.
2.Remove filler plug and gasket from transmission case.
3.Remove rear extension upper cover with the following procedure.
a.Remove rear extension upper cover mounting bolts while holding rear extension upper cover.
b.Remove rear extension upper cover and rear extension upper cover gasket from rear extension.





4.Remove check select spring and check ball from rear extension.

CAUTION:
Never drop check ball.
5.Remove control rod with the following procedure.
a.Remove control rod boot from control rod.





b.Remove boot (1) from control rod as shown in the figure.
c.Remove retaining pin (Black arrow) from control rod using a pin punch
[Commercial service tool] and then remove control rod from striking rod.
d.Remove boot from striking rod oil seal.
6.Remove park/neutral position (PNP) switch and plunger from rear extension.
7.Remove back-up lamp switch from rear extension.





8.Remove mounting bolts (Black arrow) and then remove control bracket from rear extension.





9.Remove return spring plungers (1), return springs (2), and return spring plugs (3) from rear extension.

CAUTION:
Return spring and return spring plunger have different lengths for right and left sides. Identify right and left side and then store.





10.Remove rear oil seal from rear extension using the puller [SST:
KV381054S0 (J-34286)].

CAUTION:
Never damage rear extension.
11.Remove brackets from rear extension.
12.Remove control lever housing from rear extension.

CAUTION:
Never hold control lever housing to prevent the bushing of control lever housing from deformation when moving transmission assembly.
13.Remove rear extension from adapter plate using a soft hammer.

CAUTION:
Never drop reverse idler thrust washer.
14.Remove striking rod oil seal from rear extension.

CAUTION:
Never damage rear extension.
15.Remove dust cover from rear extension.

CAUTION:
Never damage rear extension.
16.Remove oil gutter with the following procedure.
a.Remove oil gutter from rear extension.
b.Remove cap from oil gutter.





17.Remove reverse idler shaft assembly (Black arrow) from adapter plate.
18.Remove front cover with the following procedure.





a.Remove mounting bolts (Black arrow) and sealing bolts (1).
b.Remove front cover and front cover gasket from transmission case.





c.Remove front oil seal from front cover using a flat-bladed screwdriver.

CAUTION:
Never damage front cover.
19.Remove transmission case with the following procedure.





a.Remove baffle plate mounting nut (Black arrow) from transmission case.





b.Remove snap ring from main drive gear bearing using snap ring pliers.





c.Carefully tap transmission case using a soft hammer (A) and then separate adapter plate and transmission case.

CAUTION:
Never drop counter front bearing.





20.Remove counter front bearing (1) from transmission case.
21.Remove breather tube from transmission case.

CAUTION:
Never damage transmission case.
22.Remove bracket from transmission case.

SHIFT FORK AND FORK ROD






1.Install adapter setting plate (A) [SST: ST22490000 ( - )] to adapter plate and then fixing in adapter setting plate [SST:
ST22490000 ( - )] using a vise.

CAUTION:
Never directly secure the surface in a vise.
2.Remove baffle plate and oil gutter from adapter plate.
3.Remove magnet from adapter plate.





4.Remove check balls (1), check ball springs (2), and check ball plugs (3) from adapter plate.

CAUTION:
Never drop check ball.





5.Remove 3rd-4th control lever (1) and shifter cap (2) from adapter plate.

CAUTION:
Never lose shifter cap.





6.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove striking lever (1) and striking rod (2).





7.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove 3rd-4th shift fork (1) and 3rd-4th fork rod (reversal side) (2).





8.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove 3rd-4th fork rod (1) and 3rd-4th fork rod bracket (2).





9.Remove check balls (1) from adapter plate.






CAUTION:
Never drop check ball.
10.Remove interlock pin (2) from 1st-2nd fork rod.

CAUTION:
Never drop interlock pin.





11.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove 1st-2nd shift fork (1) and 1st-2nd fork rod (2).





12.Remove interlock plunger (1) from adapter plate.





13.Remove interlock pin (2) from reverse fork rod.

CAUTION:
Never drop interlock pin.





14.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove reverse shift fork (1) and reverse fork rod (2).

CAUTION:
Never drop reverse coupling sleeve.





15.Remove check balls (1) from adapter plate.






CAUTION:
Never drop check ball.





16.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove 5th-6th fork rod bracket (1) and 5th6th fork rod (2).





17.Remove 5th-6th control lever from adapter plate.










18.Remove retaining pin (Black arrow) using a pin punch [Commercial service tool] and then remove 5th-6th shift fork (1) and 5th-6th fork rod (reversal side) (2).

SHAFT AND GEAR

1.Remove reverse synchronizer hub with the following procedure.
a.Remove snap ring from mainshaft.
b.Remove snap ring from reverse synchronizer hub.
c.Remove reverse spread spring, reverse shifting inserts, and reverse coupling sleeve from reverse synchronizer hub.





d.Set a puller [Commercial service tool] to reverse main gear.
e.Remove reverse synchronizer hub together with reverse main gear, reverse baulk ring, and reverse spread spring from mainshaft using a puller [Commercial service tool].
2.Remove reverse needle bearing from mainshaft.
3.Remove reverse counter gear with the following procedure.
a.Remove snap ring from counter shaft.





b.Remove reverse counter gear from counter shaft using a puller
[Commercial service tool].
4.Remove counter rear bearing spacer from counter shaft.





5.Remove mounting bolts (Black arrow) and then remove bearing retainer from adapter plate.





6.Remove snap ring from mainshaft bearing.





7.Carefully tap mainshaft with a plastic hammer and then remove mainshaft assembly, main drive gear assembly, and counter shaft assembly combined in one unit from adapter plate.





8.Remove counter rear bearing (1) from adapter plate.
9.Remove adapter plate from adapter setting plate [SST:
ST22490000 ( - )].