Manual Transmission Disassembly
Manual Transmission Disassembly
Exploded View - Rear Cover
Exploded View - Transmission Housing
Exploded View - Clutch Housing
Special Tools Required
- Holder handle 07JAB-001020A
- Mainshaft holder 07PAB-001A300
- Companion flange holder 07RAB-TB4010B
- Adjustable bearing puller, 20-40 mm 07736-A01000B
Rear Cover Removal
NOTE: Place the clutch housing on two piece of wood thick enough to keep the mainshaft from hitting the workbench.
1. Remove the four bolts, and remove the shift lever housing (A).
2. Lower the shift rod (A), then remove the 8 mm special bolt (C), the conical spring washer (D), and shift arm B.
3. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
4. Remove the rear cover (A) and the 14 x 20 mm dowel pins (B).
5. Remove the shift rod tube and the O-rings from the rear cover.
6. Pry up the 27 mm locknut tab from the groove in the secondary shaft.
7. Install the holder handle (A) and the companion flange holder (B) onto the companion flange, and loosen the 27 mm locknut.
8. Remove the 27 mm locknut (A), the spring washer (B), the back-up ring (C), and the O-ring (D).
9. Remove the companion flange (A) using commercially available bearing puller (B) as shown.
10. Remove the oil seal from the rear cover.
11. Remove the secondary shaft (A) from the rear cover (B) using a press (C) as shown.
12. Remove the ball bearing (D) from the rear cover.
13. Remove the bearing outer race (A) and the shim (B) from the rear cover (C).
14. Remove the bearing outer race (A) from the rear cover (B) using the 20-40 mm adjustable bearing puller (C) and a commercially available 3/8''-16 UNF slide hammer (D).
Transmission Housing Removal
1. Remove the oil pump gear shaft (A) and oil pump gear (B).
2. Pry up the 29 mm locknut tab from the groove in the countershaft.
3. Install the mainshaft holder (A) onto the mainshaft spline, and loosen the 29 mm locknut (left-hand threads).
4. Remove the 29 mm locknut (A) and the spring washer (B).
5. Remove the needle bearing (A) using a commercially available bearing puller (B) as shown.
6. Remove the secondary drive gear (A) using a commercially available bearing puller (B) as shown.
7. Remove the 6 mm flange bolts, then remove the oil pump plate (A), the spring (B), the steel ball (C), and the oil pump rotors (D).
8. Remove the drain plug (A), the filler plug (B), the 12 mm drain plug (C), with the washers. Remove the set screws (D), the springs, the steel balls, and the vehicle speed sensor (VSS) ('00-05 models) or the output shaft (countershaft) speed sensor ('06-09 models) (E) with the O-ring.
9. Remove the set screws (A), the springs, the steel balls, the back-up light switch (B) with the sealing washer.
10. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
11. Remove the transmission housing and the 14 x 20 mm dowel pins (A).
12. Remove the bearing outer race (A) using the 20-40 mm adjustable bearing puller (B) and a commercially available 3/8''-16 UNF slide hammer (C), then remove the 82 mm shim (D) and oil guide plate S.
13. Remove the 16 x 26 x 7 mm oil seal from the transmission housing.
14. Remove the circlip (A), then remove the suction guide (B) and the oil pump strainer (C) from the transmission housing.
15. Remove the 82 mm shim(s) (A) and oil guide plate M.
16. Remove the oil guide pipe (A) and the magnet (B).
17. Remove the 8 mm flange bolt (A) and the washer (B), then remove the reverse shaft holder (C), the thrust washer (D), the reverse gear shaft (E), and the needle bearing (F).
18. Remove the 10 mm flange bolt (A), then remove the 8 x 63 mm pin (B) and the 1st/2nd shift levers (C).
19. Remove the 5 x 25 mm spring pin (B) from shift arm A using a 5 mm pin driver, then remove the shift rod (C).
20. Remove shift arm A from the interlock (D), then remove the select return spring (E) and the 8 x 40 mm pin (F).
21. Remove the 1st/2nd shift piece (A).
22. Remove the 34 mm sealing bolt (A) from the clutch housing.
23. Expand the 68 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using snap ring pliers.
24. Remove the mainshaft (C), the countershaft (D), and the shift forks assembly (E), and remove the 64 mm spring washer (F), the reverse idler gear (G), and thrust washer (H).
25. Remove the 6 mm flange bolts (A) and the release bearing guide (B).
26. Remove the 8 mm special bolts (C), the clutch release hanger (D), and the release hanger spring (E).
27. Remove the 6 mm flange bolt (F) and the breather plate (G).
28. Remove the oil seal from the clutch housing.
