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 mounting bolts.
4. Remove rear extension upper cover and rear extension upper cover gasket from rear extension.
5. Remove check select spring and check ball from rear extension.
6. Remove retaining pin using a pin punch [Commercial service tool] and then remove control rod and boots.
7. Remove park/neutral position (PNP) switch, plunger, and backup lamp switch from rear extension.
8. Remove control bracket mounting bolts and then remove check shift pin and control bracket as one unit from rear extension.
9. Remove right and left return spring plugs and then remove return springs and return spring plungers 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 bracket mounting bolts and then remove brackets from rear extension.
11. Remove rear oil seal from rear extension using the puller [SST:
KV381054S0 (J-34286)].
CAUTION:
Never damage rear extension.
12. Remove rear extension mounting bolts and then remove rear extension assembly using a soft hammer.
CAUTION:
Never hold control lever housing to prevent the bushing of control lever housing from deformation when moving transmission assembly.
13. Remove control lever housing mounting bolts and then remove control lever housing from rear extension.
14. Remove striking rod oil seal from rear extension.
CAUTION:
Never damage rear extension.
15. Remove rear extension dust cover from rear extension.
16. Remove rear extension oil gutter and cap from rear extension.
17. Remove counter end bearing from rear extension.
18. Remove reverse idler thrust washer, reverse idler gear and reverse idler needle bearing from reverse idler shaft.
19. Remove reverse idler shaft from adapter plate.
20. Remove front cover mounting bolts ( ) and sealing bolts (1).
21. Remove front cover and front cover gasket from transmission case.
22. Remove front cover oil seal from front cover using a flat-bladed screwdriver.
CAUTION:
Never damage front cover mating surface.
23. Remove baffle plate mounting nut from transmission case.
24. Remove snap ring from main drive gear bearing using a snap ring pliers.
25. Using a soft hammer to carefully tap mainshaft and counter shaft from transmission case side and then separate adapter plate and transmission case.
26. Remove counter front bearing from transmission case.
27. Remove oil gutter and breather tube from transmission case.
28. Remove bracket mounting bolt and then remove bracket from transmission case.
SHIFT FORK AND FORK ROD
1. Install adapter setting plate [SST: ST22490000 ( - )] to adapter plate and then fixing in adapter setting plate using a vise.
CAUTION:
Never directly secure the surface in a vise.
2. Remove baffle plate mounting bolts and then remove baffle plate from adapter plate.
3. Remove retaining pin using a pin punch [Commercial service tool] and then remove striking lever and striking rod.
4. Remove retaining pin using a pin punch [Commercial service tool] and then remove stopper ring from striking rod.
5. Remove retaining pin using a pin punch [Commercial service tool] and then remove low/high control lever from striking rod.
6. Remove check ball plugs and then remove check ball springs and check balls from adapter plate.
7. Remove 3rd-4th control lever mounting bolts and then remove
3rd-4th control lever and shifter cap.
CAUTION:
Never lose shifter cap.
8. Remove check ball plug and then remove check ball spring and check ball from adapter plate.
9. Remove retaining pin ( ) using a pin punch [Commercial service tool] and then remove 3rd-4th fork rod bracket (2) and 3rd-4th fork rod (1).
10. Remove retaining pin ( ) using a pin punch [Commercial service tool] and then remove 3rd-4th shift fork (1) and 3rd-4th fork rod (reversal side) (2).
11. Remove check balls and interlock pin from adapter plate.
12. Remove retaining pin using a pin punch [Commercial service tool] and then remove 1st-2nd shift fork and 1st-2nd fork rod.
13. Remove interlock plunger and interlock pin from adapter plate.
14. Remove retaining pin using a pin punch [Commercial service tool] and then remove reverse shift fork and reverse fork rod.
15. Remove check balls from adapter plate.
16. Remove 5th-6th control lever mounting bolts and then remove
5th-6th control lever from adapter plate.
17. Remove retaining pin using a pin punch [Commercial service tool] and then remove 5th-6th fork rod bracket and 5th-6th fork rod.
18. Remove retaining pin using a pin punch [Commercial service tool] and then remove 5th-6th fork rod (reversal side) and 5th-6th shift fork.
SHAFT AND GEAR
1. Before disassembly, measure end play for each position. If the end play is outside the specifications, disassemble
and inspect
- Mainshaft
End play standard value : Refer to TM-78, "End Play". End Play
- Counter shaft
End play standard value : Refer to TM-78, "End Play". End Play
2. Remove snap ring from mainshaft.
3. Remove snap ring from reverse synchronizer hub.
4. Remove reverse spread springs, reverse shifting inserts, and reverse coupling sleeve from reverse synchronizer hub.
5. Remove reverse main gear, reverse baulk ring, and reverse synchronizer hub assembly using a puller [Commercial service tool].
6. Remove reverse main needle bearing.
7. After removing snap ring, using a puller [Commercial service tool] to remove reverse counter gear and counter rear bearing spacer.
8. Remove mainshaft bearing retainer mounting bolts and then remove mainshaft bearing retainer.
9. Remove snap ring from mainshaft bearing.
10. Carefully tap mainshaft with a plastic hammer and then remove mainshaft assembly, main drive gear assembly and counter shaft assembly from adapter plate.
11. Remove counter rear bearing from adapter plate.
12. Remove magnet from adapter plate.