Manual Transmission Disassembly

Manual Transmission Disassembly

Exploded View - Clutch Housing





Exploded View - Transmission Housing





NOTE: Place the clutch housing on two pieces of wood that are thick enough to keep the mainshaft from hitting the workbench.

1. Remove the release bearing and the release fork.

2. Remove the set screws (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).





3. Remove the 20 mm bolt (E) and the 20 mm sealing washer (F).

4. Remove the change lever assembly (A) and the 8 x 10 mm dowel pins (B).






5. Remove the back-up light switch (A), the 18 mm sealing washer (B), and the transmission hanger (C).






6. Remove the drain plug (A), the filler plug (B), the 14 mm sealing washer (C), the 20 mm searing washer (D), the output shaft (countershaft) speed sensor (E), and the O-ring (F).






7. Remove the 8 x 1.25 mm flange bolts (A) in a crisscross pattern in several steps.






8. Remove the 32 mm sealing cap (A).






9. Expand the 69 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.

10. Remove the transmission housing (C) and the 14 x 20 mm dowel pins (D).

11. Remove the reverse shift fork (A).






12. Remove the reverse idler gear (A) and the reverse gear shaft (B).






13. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

NOTE: Do not apply tape so thick that it damages the oil seal.





14. Remove the 36 mm spring washer (E) and the 26 mm washer (F).

15. Remove the differential assembly (A) and the magnet (B).






16. Remove the oil gutter plate (A), the oil guide plate M, and the 52 x 62 mm shim (B) from the transmission housing (C).