Component Parts Removal and Installation

BASIC SUBASSEMBLY SEPARATION
1. Remove back-up light switch with gasket.
Torque: 40 Nm (30 ft. lbs.).
2. Remove bolt and vehicle speed sensor driven gear.
Torque: 13 Nm (108 inch lbs.).
3. Remove clutch housing from transmission case. Remove the nine bolts and clutch housing.
Torque: 37 Nm (27 ft. lbs.)
4. Remove control shift lever arm, dust boot and no.1 control shift yoke, as follows:





a. Remove the three bolts, nut and control shift lever arm.
Torque:
Nut A: 25 Nm (18 ft. lbs.).
Bolt B: 19 Nm (14 ft. lbs.).
b. Remove the dust boot, bolt, nut and No.1 control shift yoke.
Torque:
Nut C: 19 Nm (14 ft. lbs.).
5. Remove control shift lever retainer assembly.
a. Remove the six bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 18 Nm (13 ft. lbs.).
b. Remove the control shift lever retainer assembly and oil deflector.
6. Remove two restrict pins and gaskets.

INSTALLATION NOTE: Install the black pin on the reverse gear/5th gear side.
Torque: 40 Nm (30 ft. lbs.).

7. Remove extension housing, as follows:





a. Remove the shift lever housing set bolt.
Torque: 39 Nm (29 ft. lbs.).
b. Remove the nine bolts from the extension housing.
Torque: 37 Nm (27 ft. lbs.).
c. Using a plastic hammer, carefully tap the extension housing.
d. Disengage the shift and select lever from the shift head.





e. Pull out the extension housing.
Formed In Place Gasket (FIPG:) THREE BOND 1281 or equivalent
8. Remove front bearing retainer and bearing snap ring, as follows:
a. Remove the seven bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 Nm (18 ft. lbs.).





b. Remove the front bearing retainer.
FIPG: THREE BOND 1281 or equivalent
c. Using a snap ring expander, remove the two bearing snap rings.
9. Separate intermediate plate from transmission case, as follows:





a. Using a plastic hammer, carefully tap the transmission case.
b. Pull the transmission case from the intermediate plate.

INSTALLATION NOTE: Align each bearing outer race and each shift fork shaft end with the case holes.

FIPG: THREE BOND 1281 or equivalent
10. Mount intermediate plate in vise, as follows:





a. Use the two long clutch housing bolts, plate washers and suitable nuts, as shown.

REMOVAL NOTICE: Increase or decrease plate washers so that the bolt tip does not protrude from the nut.

b. Mount the intermediate plate in a vise.
11. Remove oil separator. Remove the two bolts and oil separator.
Torque: 18 Nm (13 ft. lbs.).
12. Remove front magnet.
13. Remove locking ball and spring, as follows:





a. Using a hexagon wrench, remove the four straight screw plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 25 Nm (18 ft. lbs.).
b. Using a magnetic finger, remove the three springs and bails.
14. Remove shift fork, shift fork shaft and reverse idler gear, as follows:





a. Remove the No.1 and No.2 shift forks set bolts.
Torque: 20 Nm (14 ft. lbs.).
b. Remove the bolt and reverse idler gear shaft stopper.
Torque: 25 Nm (18 ft. lbs.).
c. Remove the reverse idler gear and shaft with the snap ring.
d. Remove the No.1 shift fork and shaft.





e. Using a magnetic finger, remove the No.1 and No.2 interlock pins.

INSTALLATION NOTE: Apply Multi-Purpose (MP) grease to the No.1 and No.2 interlock pins.

f. Using two screwdrivers and a hammer, tap out the No.2 shift fork shaft snap ring.
g. Remove the No. 2 shift fork and shaft.





h. Using a magnetic finger, remove the No. 3 interlock pin.

INSTALLATION NOTE: Apply MP grease to the No.3 interlock pin.





i. Using a pin punch and hammer, drive out the No. 3 shift fork pin.
j. Using a hexagon wrench, remove the plug.
Torque: 25 Nm (18 ft. lbs.).
k. Using a magnetic finger, remove the spring and ball.
l. Pull out the No.4 shift fork shaft.
m. Remove the pin from the reverse shift head.

INSTALLATION NOTE: Apply MP grease to the pin.

n. Remove the No.3 shift fork, fork shaft and reverse shift arm with the snap ring.





INSTALLATION NOTE: Align the No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove.





15. Remove vehicle speed sensor drive gear. Pry out both ends of the clip and remove the drive gear.





16. Inspect counter 5th gear thrust clearance. Using a feeler gauge, measure the counter 5th gear thrust clearance.
Standard clearance: 0.10-0.41 mm (0.0039-0.0161 inch).
Maximum clearance: 0.46 mm (0.0181 inch).
17. Remove counter rear bearing, spacer, counter 5th gear and needle roller bearing, as follows:





a. Using a snap ring expander, remove the snap ring.

INSTALLATION NOTE: Select a snap ring that will allow maximum axial play.
Marks:
1: 1.90-1.95 mm (0.0478-0.0768 inch).
2: 1.96-2.01 mm (0.0772-0.0791 inch).
3: 2.02-2.07 mm (0.0795-0.0815 inch).
4: 2.08-2.13 mm (0.0819-0.0839 inch).
5: 2.14-2.19 mm (0.0843-0.0862 inch).
6: 2.20-2.25 mm (0.0866-0.0886 inch).
7: 2.26-2.31 mm (0.0890-0.0909 inch).





b. Using Special Service Tool (SST) 09950-40010 or equivalent, remove the rear bearing, spacer, counter 5th gear and bearing.

REMOVAL NOTICE: Be careful not to catch the output shaft rear bearing roller on the counter 5th gear.

c. Remove the spacer.

INSTALLATION NOTE:





- Install the counter 5th gear with the 5th gear gaps aligned with the synchronizer cone ring pin.
- Using a socket wrench and hammer, drive in the bearing.
- When driving in the bearing, support the counter shaft in front with a 3-5 lb. hammer or equivalent.

18. Remove synchronizer ring assembly with No.3 hub sleeve and No.3 clutch hub, as follows:





a. Remove the synchronizer ring assembly with the No.3 hub sleeve from the No.3 clutch hub.
b. Remove the spacer.





c. Using two screwdrivers and a hammer, tap out the snap ring.

INSTALLATION NOTE: Select a snap ring that will allow minimum axial play.

Marks:
2: 2.06-2.11 mm (0.0811-0.0831 inch).
3: 2.12-2.17 mm (0.0835-0.0854 inch).
4: 2.18-2.23 mm (0.0858-0.0878 inch).
5: 2.24-2.29 mm (0.0882-0.0902 inch).





d. Using SST 09950-40010 or equivalent, remove the No.3 clutch hub.

INSTALLATION NOTE:





- Using SST 09316-60011 (09316-00011, 09316-00071) or equivalents, and a hammer, drive in the No.3 clutch hub.
- When installing the No.3 clutch hub, support the counter shaft in front with a 3-5 lb. hammer or equivalent.

19. Remove rear magnet.
20. Remove output shaft rear bearing and 5th gear, as follows:





a. Using two screwdrivers and a hammer, tap out the snap ring.

INSTALLATION NOTE: Select a snap ring that will allow minimum axial play.

Marks:
8: 2.31-2.36 mm (0.0909-0.0929 inch)
9: 2.37-2.42 mm (0.0933-0.0953 inch).
10: 2.43-2.48 mm (0.0957-0.0976 inch).
11: 2.49-2.54 mm (0.0980-0.1000 inch).
12: 2.55-2.60 mm (0.1004-0.1024 inch).
13: 2.61-2.66 mm (0.1028-0.1047 inch).
14: 2.68-2.73 mm (0.1055-0.1075 inch).
15: 2.74-2.79 mm (0.1079-0.1098 inch).





b. Using SST 09312-20011 (09313-00030,09313-00040, 09313-00050) or equivalents, remove the rear bearing and 5th gear.





INSTALLATION NOTE: Using SST 09312-20011 (09313-00030,09313-00040, 09313-00050) or equivalents, install the 5th gear and rear bearing.

21. Remove reverse gear, as follows:





a. Using a snap ring expander, remove the snap ring.





INSTALLATION NOTE: Select a snap ring that will allow minimum axial play.





b. Using SST 09950-40010 or equivalent, remove the reverse gear.





INSTALLATION NOTE: Using SST 09312-20011 (09313-00030, 09313-00040,09313-00050) or equivalents, install the reverse gear.

22. Remove rear bearing retainer, as follows:
a. Using a torx socket wrench (T40), unscrew the four torx screws and remove the rear bearing retainer.
Torque: 18 Nm (13 ft. lbs.).
b. Using a snap ring expander, remove the 2 snap rings.

INSTALLATION NOTE: Be sure the snap ring is flush with the intermediate plate surface.

23. Remove output shaft and counter gear from intermediate plate, as follows:





a. Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
b. Remove the input shaft from the output shaft.

INSTALLATION NOTE:





- Before installing the output shaft, use SST 09950-60010 (09951-00510), 09950-70010 (09951-07150) or equivalents, to remove the counter gear center bearing outer race.
- Install the outer race after installing the counter gear.
- Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.
- Apply gear oil to the needle roller bearing.
- Install the needle roller bearing to the input shaft.
- Install the input shaft and counter gear together.





- Using SST 09316-60011 (09316-00011) or equivalents, and a hammer, install the counter gear center bearing outer race.
- Be careful not to damage the bearing rollers.

BASIC SUBASSEMBLY REASSEMBLY
Assembly is in the reverse order of disassembly.

NOTE: Coat all of the sliding and rotating surfaces with gear oil before assembly.