Disassembly

DISASSEMBLY








Case Components





1. Remove rear extension upper cover mounting bolts, rear extension upper cover and rear extension upper cover gasket from rear extension.





2. Remove check select spring and check ball from rear extension.





3. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove control rod.
4. Remove PNP switch, plunger and back-up lamp switch from rear extension.





5. Remove control bracket mounting bolts. Then remove check shift pin and control bracket as one unit from rear extension.





6. Remove right and left return spring plugs. Then remove return spring and return spring plunger from rear extension.

CAUTION: Return springs and return spring plungers have different lengths for right and left sides. Identify right and left side and then store.





7. Remove rear oil seal from rear extension using the oil seal puller.
Tool number: KV381054S0 ( - )





8. Remove rear extension mounting bolts. Using a soft hammer, tap rear extension assembly to remove.

CAUTION: Do not hold control lever housing to prevent bushing of control lever housing from deformation when moving transmission assembly.

9. Remove control lever housing mounting bolts and control lever housing from rear extension.
10. Remove striking rod oil seal from rear extension. Refer to MT-21, Case Components.
11. Remove rear extension oil gutter mounting bolt and rear extension oil gutter from rear extension. Refer to MT-21, Case Components.





12. Remove reverse idler thrust washer, reverse idler gear and reverse idler needle bearing from reverse idler shaft.
13. Remove reverse idler shaft from adapter plate.





14. Remove withdrawal lever ball pin and washer from front cover.
15. Remove front cover mounting bolts. Then remove front cover and front cover gasket from transmission case.





16. Remove front cover oil seal from front cover using a flat-bladed screwdriver.

CAUTION: Be careful not to damage front cover mating surface.





17. Remove baffle plate mounting nut from transmission case.





18. Remove snap ring from main drive gear bearing using snap ring pliers.





19. Carefully tap on transmission case to separate it from adapter plate using a soft hummer.





20. Remove counter front bearing from transmission case.
21. Remove oil gutter from transmission case.

Shift Control Components





1. Install adapter setting plate to adapter plate, and then secure adapter setting plate in a vise.
Tool number: ST22490000 ( - )





2. Remove baffle plate mounting bolts and baffle plate from adapter plate.

NOTE: Mounting bolts are installed both from the front side and the reverse side of adapter plate.

3. Remove magnet from adapter plate.





4. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove striking lever and striking rod.





5. Remove check ball plugs, check ball springs and check balls from adapter plate.





6. Remove 3rd-4th control lever mounting bolts and 3rd-4th control lever from adapter plate.
7. Remove shifter cap from 3rd-4th control lever.





8. Remove check ball plug, check ball spring and check ball from adapter plate.





9. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 3rd-4th fork rod bracket and 3rd-4th fork rod.





10. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 3rd-4th fork rod (reversal side) and 3rd-4th shift fork.





11. Remove check balls and interlock pin from adapter plate.





12. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 1st-2nd fork rod and 1st-2nd shift fork.





13. Remove interlock plunger and interlock pin from adapter plate.





14. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove reverse fork rod and reverse shift fork.





15. Remove check balls from adapter plate.





16. Remove 5th-6th control lever mounting bolts, and 5th-6th control lever from adapter plate.





17. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 5th-6th fork rod and 5th-6th fork rod bracket.





18. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 5th-6th fork rod (reversal side) and 5th-6th shift fork.

Gear Components
^ Before disassembly, measure end play for each position. If the end play is outside the specifications, disassemble and inspect.

- Main drive gear
End play: 0 - 0.1 mm (0 - 0.004 inch)





- Main shaft rear side
End play: 0 - 0.1 mm (0 - 0.004 inch)





- Counter shaft
End play: 0 - 0.1 mm (0 - 0.004 inch)





1. After removing snap ring, remove reverse synchronizer assembly and reverse main gear from main shaft using a puller.
2. Remove reverse main needle bearing from mainshaft.





3. Remove main shaft bearing retainer mounting bolts and main shaft bearing retainer from adapter plate.





4. After removing snap ring, remove reverse counter gear and counter rear bearing spacer using a puller.





5. Remove snap ring from main shaft bearing.





6. Remove main shaft assembly and counter shaft assembly together from adapter plate.





7. Remove counter rear bearing from adapter plate.
8. Remove main drive gear, main pilot bearing, pilot bearing spacer and 5th baulk ring from mainshaft.





9. Remove snap ring from main drive gear using snap ring pliers.





10. Set a puller on main drive gear bearing, and remove main drive gear bearing from main drive gear using a press.





11. Set a puller on 4th main gear, and remove reverse main gear bushing, main shaft bearing and 4th main gear from main shaft using a press.
12. Remove 3rd-4th main spacer from mainshaft.





13. Set a puller on 1st main gear, and remove 3rd main gear and 1st main gear from main shaft using a press.

CAUTION: Be careful not to damage baulk ring.

14. Remove 1st needle bearing from mainshaft.





15. Set a puller on 2nd main gear, and remove 1st-2nd synchronizer assembly and 2nd main gear from main shaft using a press.

CAUTION: Be aware that when using the press, if the main shaft gear positioner catches on the V-block, etc., the main shaft could be damaged.

16. Remove 2nd needle bearing from the main shaft.





17. Remove snap ring, then set a puller on 6th main gear, and remove 5th-6th synchronizer assembly, 6th baulk ring and 6th main gear from main shaft using a press.
18. Remove 6th needle bearing from mainshaft.





19. Set a puller on 3rd counter gear, and remove counter rear bearing inner race, 4th counter gear thrust washer, 4th counter gear, 4th inner baulk ring, 4th synchronizer cone, 4th outer baulk ring, 4th needle bearing, 4th gear bushing, 3rd-4th synchronizer assembly, 3rd outer baulk ring, 3rd synchronizer cone, 3rd inner baulk ring and 3rd counter gear from counter shaft using a press.
20. Remove 3rd needle bearing from counter shaft.





21. Set a puller on 3rd gear bushing, and remove 3rd gear bushing from counter shaft using a press.

CAUTION: Do not use oil hole of 3rd gear bushing when press out.