Disassemble

1. Remove bell housing-to-transmission case attaching nuts, then the bell housing and gasket.

Sectional View Of Toyo Kogyo (Models W/Gasoline Engine) 4-Speed Manual Transmission:

2. Remove drain plug and drain lubricant from transmission. If necessary, clean metal filings from plug and reinstall.
3. Place transmission in neutral.
4. Remove 4 gearshift lever retainer-to-extension housing attaching bolts, then the retainer and gasket.
5. Remove 6 bolts attaching extension housing to transmission case.
6. Raise control lever to the left and slide toward rear of transmission.
7. Slide extension housing off transmission being careful not to damage the oil seal.

NOTE: If necessary remove gearshift control lever end and control by removing attaching bolt. If required also remove back-up lamp switch from extension housing.

8. Remove anti-spill seal from output shaft and discard, seal is not necessary for reassembly.
9. Remove snap ring from speedometer drive gear. Slide drive gear off mainshaft and remove lock ball.
10. Evenly loosen 14 bolts securing transmission case cover to transmission case and remove cover and gasket.

Detent Spring & Ball Removal:

11. Remove 3 spring cap bolts. Remove detent springs and balls from transmission using a magnet.
12. Remove 4 blind covers-to-transmission case attaching bolts, and remove blind covers and gasket.
13. Slide reverse shift fork shaft assembly and idler gear out of transmission case.
14. Shift transmission into 4th gear. With a small drift, drive roll pin from 3rd and 4th fork assembly. Slide 3rd-4th shift fork shaft out of transmission case.
15. Remove roll pin from 1st-2nd shift fork. Slide shift fork out of transmission case. Remove inter-lock pins.
16. Reinstall reverse idler gear then install tool No. T77J-7025-E between 4th speed synchronizer ring and synchromesh gear on mainshaft, and shift transmission into 2nd gear.

Removing Or Installing Locknut:

17. Fold back ends of lockwasher then remove locknut and washer, slide reverse idler gear off mainshaft.
18. Remove key from mainshaft then remove reverse idler gear.
19. Remove snap ring from end of countershaft, and slide reverse gear off countershaft.
20. Remove 4 bearing retainer attaching bolts then remove bearing retainer together with reverse idler gear shaft.

Countershaft Rear Bearing Removal:

21. Remove countershaft rear bearing using a suitable puller.

Positioning Of The Retainer Ring For Removal:

NOTE: The retainer ring may need to be turned to position the split in the retainer ring midway between the recessed areas, before the puller is installed. This will reduce the possibility of the retainer ring becoming distorted as the bearing is removed.

22. Turn forcing screw clockwise to remove bearing.

Mainshaft Rear Bearing & Mainshaft Drive Gear Bearing Removal:

23. Remove mainshaft rear bearing using suitable puller. Turn forcing screw clockwise to remove bearing.
24. Remove shim and spacer from behind mainshaft rear bearing.
25. Remove 4 studs and bolts attaching front cover to case and remove front cover. Save shim on inside of the cover.
26. Remove snap ring from input shaft.
27. Remove mainshaft drive gear bearing using suitable puller. Turn forcing screw clockwise to remove bearing.

Positioning Input Shaft Flats:

28. Rotate both shift forks so that main gear train will fall to bottom of case. Remove shift forks. Rotate input shaft so that one of two flats on input shaft face upward.
29. Remove snap ring from front of countershaft.

Countershaft Removal:

30. Install tool No. T77J-7025-E between 1st gear on countershaft and rear of case.
31. Install tools No. T75L-7025-J, T82T- 7003-BH and T77J-7025-N.
32. Turn forcing screw clockwise until countershaft contacts tool No. T77J-7025-E.
33. Remove countershaft front bearing using suitable puller. Turn forcing screw clockwise.
34. Remove shim from behind countershaft front bearing.
35. Remove input shaft from transmission case then remove synchronizer ring and caged bearing from main driveshaft.
36. Remove countershaft from transmission case.
37. Remove inner race of countershaft center bearing from countershaft, using suitable press.
38. Remove mainshaft and gear assembly from transmission case.

Exploded View Of Shafts & Gears:

39. Remove snap rings from front of mainshaft. Slide clutch hubs, sleeve assembly synchronizer ring, gears and thrust washer from mainshaft.
40. Remove thrust washer, 1st gear and sleeve and the 1st and clutch hub and sleeve from mainshaft. Remove bushing from 1st gear using a suitable press.

NOTE: Do not mix the synchronizer rings.