Transmission Disassembly

1. Remove bolt and disconnect back-up light switch clamp. Remove back-up light switch with gasket. Remove bolt and vehicle speed sensor driven gear. Remove 9 bolts and remove clutch housing from transmission case. Remove 6 bolts and control shift lever retainer and oil deflector from extension housing. See Fig 1.
2. Using 10-mm hexagon wrench, remove straight screw plug from control shift lever retainer. Using a magnet, remove compression spring and lock ball pin. See Fig 1. Remove 2 colored restrict pins and gaskets. See Fig 3. Remove shift lever housing set bolt. See Fig 4. Remove 9 bolts and wire harness clamp from extension housing. See Fig 1.
3. Using plastic hammer, tap extension housing. Pull out extension housing with shift and select lever and inner lever. Disengage shift and select lever from shift lever housing. Remove extension housing. Remove 7 bolts and front bearing retainer. Remove oil seal from bearing retainer. Remove 2 bearing snap rings.
4. Using plastic hammer, carefully tap transmission case. Pull transmission case from intermediate plate. See Fig 1. Mount intermediate plate in vise by installing 2 clutch housing bolts with nuts and washers in bottom holes of intermediate plate to prevent damage to sealing surface of intermediate plate. See Fig 5. Increase or decrease washers so that bolt tip does not protrude from nut. DO NOT apply pressure on intermediate plate. Remove 2 bolts and oil separator. Remove front magnet. Remove 4 straight screw plugs from intermediate plate. See Fig 6. Using magnet, remove springs and locking balls.
5. Remove No. 1 and No. 2 shift fork set bolts. See Fig 7. Remove bolt and reverse idler gear shaft stopper. Remove reverse idler gear and shaft with snap ring. Remove No. 1 shift fork and shaft. See Fig 2. Using a magnet, remove No. 1 and No. 2 interlock pins. See Fig 8. Using 2 screwdrivers and a hammer, tap out snap ring from No. 2 shift fork shaft. Remove No. 2 shift fork shaft. Using a magnet, remove No. 3 interlock pin. Remove snap ring from No. 3 shift fork shaft. Using a pin punch and hammer, drive out No. 3 shift fork slotted spring pin. See Figure. Remove straight screw plug, spring and ball. See Fig 2.
6. Pull out No. 4 shift fork shaft. Remove pin from reverse shift head. See Fig 9. Remove No. 3 shift fork, fork shaft and reverse shift arm with snap ring. Remove shift arm shoe (if equipped). Using a screwdriver, remove "E" ring and separate reverse shift head and reverse shift arm. Pry out both ends of clip and remove vehicle speed sensor drive gear from shaft. See Fig 2.
NOTE: Ensure output shaft rear bearing roller and counter 5th gear do not contact each other when removing gear.
7. Using a feeler gauge, measure counter 5th gear thrust clearance. See Fig 10. Standard clearance is .004-.016" (.10-.41 mm). Service limit is .016" (.41 mm). Remove 5th gear snap ring on countergear. See Fig 11. Using 2-jaw puller, remove countergear rear bearing, spacer, counter 5th gear, needle roller bearing and spacer. See Fig 2.
8. Remove synchronizer ring assembly with No. 3 hub sleeve from No. 3 clutch hub. Remove spacer and tap out snap ring. Using puller, remove No. 3 clutch hub. Remove rear magnet. Using 2 screwdrivers and a hammer, tap out output shaft snap ring. Using appropriate puller, remove rear bearing and 5th gear. See Fig 2.
9. Remove output shaft reverse gear snap ring. Using puller, remove reverse gear. Using Torx (T40) socket, remove bearing retainer screws and retainer. Remove bearing snap rings. Using a plastic hammer, tap intermediate plate and remove output shaft with input shaft, and countergear as a unit. Remove input shaft from output shaft. See Fig 2.