Manual Transmission Disassembly
Manual Transmission Disassembly
Exploded View - Clutch Housing: 2WD
Exploded View - Clutch Housing: 4WD
Exploded View - Transmission Housing
NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
1. 2WD: Remove the side cover (A) and the O-ring (B).
2. 4WD: Remove the transfer assembly (A), the O-ring (B), and the 10 x 20 mm dowel pin (C).
3. Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (D), the steel balls (E), the back-up light switch (F), and transmission hanger C.
4. Remove the 20 mm bolt (A) and the 20 mm washer (B).
5. Remove the interlock bolt (A), then remove the change lever assembly (B) and the 8 x 14 mm dowel pins (C).
6. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), and the sealing washers (D).
7. Remove the output shaft (countershaft) speed sensor (E), the plain washer (F), and the O-ring (G).
8. Loosen the 8 mm flange bolts in a crisscross pattern in several steps.
9. Remove the 8 mm flange bolts with transmission hanger A and transmission hanger B.
10. Remove the 32 mm sealing cap (A).
11. While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C). Release the snap ring pliers, and remove the transmission housing and the three 14 x 20 mm dowel pins (D).
12. Remove the reverse lock cam (A).
13. Remove the reverse idler gear (A) and the reverse idler gear shaft (B).
14. Remove the reverse shift fork (A).
15. 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 thick to damage the oil seal.
16. Remove the 28 mm spring washer (E) and the 28 mm washer (F).
17. Remove the differential assembly (A) and the magnet (B).
18. Remove the oil gutter plate (A), the 72 mm shim (B), and oil guide plate M.
