Part 1

Transmission Disassemble




1. Remove the manual transmission filler plug and gasket from the manual transmission case.




2. Remove the drain plug sub-assembly and gasket from the manual transmission case.




3. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
4. Remove the O-ring from the speedometer driven hole cover sub-assembly.
5. Separate the back-up light switch wire harness from the clamps.
6. Remove the back-up light switch assembly and gasket from the manual transmission case.




7. Remove the bolts (1, 2), nut (3), and selecting bellcrank assembly from the manual transmission case.
8. Remove the control bellcrank dust cover.




9. Remove the nut (1) and washer.




10. Using a brass bar and a hammer, remove the lock pin.
11. Remove the floor shift control shift lever and dust boot.




12. Remove the nut (1) and washer.




13. Using a brass bar and a hammer, remove the lock pin.
14. Remove the shift lever damper and dust boot.




15. Place the manual transaxle assembly on wooden blocks (1, 2).




16. Remove the No. 1 lock ball assembly (1) from the manual transmission case.




17. Remove the shift guide pin (1) and washer from the manual transmission case.




18. Remove the bolts (1-4), control shaft cover and gasket from the manual transmission case.




19. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.




20. Remove the shift and select lever shaft assembly from the manual transmission case.




21. Remove the bolts.





Note: Do not damage the manual transmission case.

22. Using a plastic hammer, carefully tap the projections (1, 2, 3, 4) of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.




23. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.




24. Engage the gears simultaneously to lock the transmission.
25. Remove the manual transmission output shaft rear set nut.
26. Disengage the gears.




27. Remove the gear shift fork lock bolt (1) from the No. 3 gear shift fork.




28. Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.




29. Using a dial indicator, measure the 5th gear thrust clearance.

* Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)
* Maximum clearance - 0.55 mm (0.0217 in)

30. If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.




31. Using a dial indicator, measure the 5th gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

32. If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.





Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

33. Using 2 screwdrivers and a hammer, tap out the snap ring.




34. Using a screwdriver, remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.
35. Using a suitable puller, remove the No. 3 transmission clutch hub, 5th gear, and No. 3 synchronizer ring from the input shaft.




36. Remove the synchromesh shifting keys and synchromesh shifting key spring from the No. 3 transmission clutch hub.




37. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
38. Using a suitable puller, remove the 5th driven gear from the output shaft.




39. Remove the bolts (1-5) and rear bearing retainer from the manual transmission case.




40. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.




41. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.




42. Remove the reverse idler gear shaft bolt (1) and gasket from the manual transmission case.





Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

43. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.




44. Using a hexagon wrench, remove the shift detent ball plugs from the manual transmission case.




45. Using a magnetic pick-up tool, remove the shift spring seats, shift detent ball springs, and shift detent balls from the manual transmission case.




46. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.




47. Using a magnetic pick-up tool, remove the seat, spring, and ball from the transaxle case.




48. Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.




49. Remove the bolts (1-3) from the transaxle case.




50. Remove the bolts (1-13) from the manual transmission case.