Disassembly

RA62 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: DISASSEMBLY

1. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Separate the 3 clamps.

(b) Remove the bolt and bracket.

(c) Using SST, remove the back-up light switch and gasket.

SST : 09817-16011

2. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

(a) Remove the floor shift control shift lever retainer sub-assembly.

3. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER

(a) Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.

(b) Remove the floor shift control shift lever retainer.

4. REMOVE SHIFT AND SELECT LEVER BOOT

(a) Remove the shift and select lever boot.

5. REMOVE SHIFT LEVER RETAINER BUSHING

(a) Remove the 4 shift lever retainer bushings.

6. REMOVE CONTROL SHAFT

(a) Using a screwdriver, remove the E-ring and control shaft.

(b) Remove the 2 collars from the floor shift control shaft.

7. REMOVE TRANSMISSION CONTROL CABLE WEIGHT

(a) Remove the control shaft cover from the transmission control cable weight.

(b) Using a hexagon socket wrench (8 mm), remove the shift arm pivot from the extension housing sub-assembly.

(c) Remove the transmission control cable weight, 2 shift arm pivot collars and dust boot plate.

(d) Remove the shift lever boot dust seal from the dust boot plate.

8. REMOVE FLOOR SHIFT CONTROL SHAFT

(a) Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shift and select lever shaft.

(b) Using a pin punch (dia5 mm) and a hammer, remove the shaft pin and floor shift control shaft from the shift and select lever shaft.

(c) Remove the shift lever damper from the floor shift control shaft.

9. REMOVE SHIFT AND SELECT LEVER SHAFT SUPPORT

(a) Using a pin punch (dia5 mm) and a hammer, remove the slotted spring pin and shift and select lever shaft support from the shift and select lever shaft.

10. REMOVE EXTENSION HOUSING DUST DEFLECTOR

(a) Using a plastic hammer, remove the extension housing dust deflector.

11. REMOVE EXTENSION HOUSING SUB-ASSEMBLY

(a) Remove the 8 bolts.

(b) Using a plastic hammer, carefully tap out the extension housing sub-assembly.

(c) Remove the extension housing sub-assembly.

12. REMOVE REAR EXTENSION HOUSING OIL SEAL

(a) Using SST, remove the rear extension housing oil seal.

SST : 09612-70100

09612-07210

13. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Using SST, remove the extension housing oil seal.

SST : 09308-00010

14. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

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

(b) Remove the extension housing oil receiver pipe.

15. REMOVE SHIFT DETENT BALL PLUG

(a) Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the rear transmission case.

(b) Remove the ball and compression spring from the rear transmission case.

16. REMOVE OUTPUT SHAFT ADJUST NUT

(a) Using a belt and wooden block, securely fasten the transmission to the workbench.

(b) Using a chisel and hammer, unstake the nut.

(c) Engage 5th gear, and then secure the input shaft using SST.

SST : 09322-35010

09322-03010

09322-03020

09322-03030

90901-05003

90170-12030

94622-51200

HINT
* Install SST securely so that (A) is in-line with the input shaft.
* Make sure that (A) moves back and forth by hand after installing SST.

(d) Using handle L-type and SST, remove the output shaft adjust nut from the output shaft.

SST : 09326-35020

(e) Remove the belt and wooden block from the transmission.

(f) Remove the No. 2 taper roller bearing and spacer.

17. REMOVE REAR TRANSMISSION CASE

(a) Remove the 10 bolts and bracket.

(b) Using a plastic hammer, carefully tap out the rear transmission case.

(c) Remove the rear transmission case.

18. REMOVE MANUAL TRANSMISSION FILLER PLUG

(a) Remove the 2 manual transmission filler plugs and 2 gaskets from the rear transmission case.

19. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

(a) Remove the extension housing oil receiver pipe from the rear transmission case.

20. REMOVE OIL SEPARATOR PACKING SEAL

(a) Remove the oil separator packing seal from the rear transmission case.

21. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE

(a) Using SST, remove the 2 output shaft rear bearing outer races.

SST : 09308-00010

22. REMOVE COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING

(a) Remove the bolt, then remove the bearing lock plate.

(b) Using SST, remove the counter gear rear cylindrical roller bearing from the rear transmission case.

SST : 09308-00010

23. REMOVE REAR TRANSMISSION CASE BEARING

(a) Using SST and a press, remove the rear transmission case bearing from the rear transmission case.

SST : 09950-60010

09951-00230

24. REMOVE TRANSMISSION OIL SEPARATOR

(a) Remove the 2 bolts, then remove the transmission oil separator.

25. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket from the center transmission case sub-assembly.

26. REMOVE CENTER TRANSMISSION CASE SUB-ASSEMBLY

(a) Remove the 11 bolts.

(b) Using a plastic hammer, carefully tap out the center transmission case sub-assembly.

27. REMOVE TRANSMISSION DRAIN PLUG

(a) Remove the drain plug and gasket from the center transmission case sub-assembly.

28. REMOVE NO. 2 OIL RECEIVER PIPE

(a) Remove the No. 2 oil receiver pipe from the center transmission case sub-assembly.

29. REMOVE SHIFT AND SELECT LEVER SHAFT

(a) Using a screwdriver, remove the E-ring from the shift and select lever shaft.

(b) Remove the bolt from the shift and select lever.

(c) Using a pin punch (dia5 mm) and a hammer, remove the slotted spring pin from the shift and select lever.

(d) Slide the shift and select lever shaft up until it can be removed from the front transmission case.

(e) Remove the shift and select lever shaft, shift interlock plate, shift and select cam and shift and select lever from the front transmission case.

(f) Remove the lock ball pin and compression spring from the shift and select lever.

30. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.130 to 0.214 mm (0.00512 to 0.00842 in.)

Maximum clearance:

0.214 (0.00842 in.)

If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or front transmission case during reassembly.

31. REMOVE REVERSE IDLER GEAR

(a) Remove the reverse idler gear shaft, reverse idler gear bearing and reverse idler gear.

32. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

(a) Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.

(b) Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.050 mm (0.0006 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear during reassembly.

33. REMOVE FRONT TRANSMISSION CASE

(a) Using a hexagon wrench (27 mm), remove the plug from the front transmission case.

(b) Remove the 4 bolts from the shift interlock bracket.

(d) Expand the 2 front bearing shaft snap rings, and lift up the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts.

(e) Remove the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts while gently tapping the front transmission case with a plastic hammer.

NOTICE:
Take care not to subject the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts to any impact. This may cause the ball and spring to come out.

(f) Separate the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts.

34. REMOVE NO. 1 OIL RECEIVER PIPE

(a) Remove the No. 1 oil receiver pipe from the front transmission case.

35. REMOVE FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers, remove the 2 front bearing shaft snap rings.

36. REMOVE TRANSMISSION CASE OIL SEAL

(a) Using SST, remove the transmission case oil seal from the front transmission case.

SST : 09308-00010

37. REMOVE FRONT TRANSMISSION CASE BEARING

(a) Using SST, remove the front transmission case bearing from the front transmission case.

SST : 09319-60020

SST : 09350-32014

09351-32180

38. REMOVE NO. 3 GEAR SHIFT FORK

(a) Using 2 screwdrivers, remove the 4 snap rings.

(b) Remove the bolt, then remove the No. 3 gear shift fork.

39. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

(b) Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, shift detent ball and compression spring.

40. REMOVE NO. 2 GEAR SHIFT FORK

(a) Remove the bolt, then remove the No. 2 gear shift fork.

41. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

(a) Remove the No. 2 gear shift fork shaft, shift detent ball and compression spring.

42. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

(b) Remove the No. 3 gear shift fork shaft, shift detent ball, compression spring and No. 3 gear shift head.

43. REMOVE NO. 1 GEAR SHIFT FORK

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

(b) Remove the No. 2 gear shift head and No. 1 gear shift fork.

44. REMOVE NO. 4 GEAR SHIFT FORK

(a) Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

(b) Remove the No. 4 gear shift fork.

45. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

(a) Remove the No. 4 gear shift fork shaft, shift detent ball and compression spring.

46. REMOVE SHIFT ARM

(a) Using a screwdriver, remove the E-ring.

(b) Remove the shift arm pivot and shift arm.