Disassembly and Assembly: Disassembly

Case Components 

1. Remove rear extension upper cover mounting bolts, rear extension upper cover and rear extension upper cover gasket from rear extension.
   Fig 1: Transmission Disassembly (1 Of 47)

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2. Remove check select spring and check ball from rear extension.
   Fig 2: Transmission Disassembly (2 Of 47)

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3. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove control rod.
4. Remove neutral position switch, plunger and back-up lamp switch from rear extension.
   Fig 3: Transmission Disassembly (3 Of 47)

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5. Remove control bracket mounting bolts. Then remove check shift pin and control bracket as one unit from rear extension.
   Fig 4: Transmission Disassembly (4 Of 47)

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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.
   Fig 5: Transmission Disassembly (5 Of 47)

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7. Remove rear oil seal from rear extension using the oil seal puller.
   1. Tool number :KV381054S0 ( - ) 
   Fig 6: Transmission Disassembly (6 Of 47)

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8. Remove rear extension mounting bolts. Using a soft hammer, tap rear extension assembly to remove.
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 "Figure ".
11. Remove rear extension oil gutter mounting bolt and rear extension oil gutter from rear extension. Refer to "Figure ".
    Fig 7: Transmission Disassembly (7 Of 47)

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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.
    Fig 8: Transmission Disassembly (8 Of 47)

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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.
    Fig 9: Transmission Disassembly (9 Of 47)

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16. Remove front cover oil seal from front cover using a flat-bladed screwdriver.
    CAUTION: Be careful not to damage front cover mating surface.
    Fig 10: Transmission Disassembly (10 Of 47)

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17. Remove baffle plate mounting nut from transmission case.
    Fig 11: Transmission Disassembly (11 Of 47)

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18. Remove snap ring from main drive gear bearing using snap ring pliers.
    Fig 12: Transmission Disassembly (12 Of 47)

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19. Carefully tap on transmission case to separate it from adapter plate using a soft hummer.
    Fig 13: Transmission Disassembly (13 Of 47)

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20. Remove counter front bearing from transmission case.
21. Remove oil gutter from transmission case.
    Fig 14: Transmission Disassembly (14 Of 47)

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Shift Control Components 

1. Install adapter setting plate to adapter plate, and then secure adapter setting plate in a vise.
   1. Tool number :ST224490000 (-) 
   Fig 15: Transmission Disassembly (15 Of 47)

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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.
   Fig 16: Transmission Disassembly (16 Of 47)

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3. Remove magnet from adapter plate.
4. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove striking lever and striking rod.
   Fig 17: Transmission Disassembly (17 Of 47)

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5. Remove check ball plugs, check ball springs and check balls from adapter plate.
   Fig 18: Transmission Disassembly (18 Of 47)

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6. Remove 3rd-4th control lever mounting bolts and 3rd-4th control lever from adapter plate.
   Fig 19: Transmission Disassembly (19 Of 47)

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7. Remove shifter cap from 3rd-4th control lever.
8. Remove check ball plug, check ball spring and check ball from adapter plate.
   Fig 20: Transmission Disassembly (20 Of 47)

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9. Drive out retaining pin using a pin punch [6mm (0.24in) dia.], and remove 3rd-4th fork rod bracket and 3rd-4th fork rod.
   Fig 21: Transmission Disassembly (21 Of 47)

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10. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove 3rd-4th fork rod (reversal side) and 3rd-4th shift fork.
    Fig 22: Transmission Disassembly (22 Of 47)

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11. Remove check balls and interlock pin from adapter plate.
    Fig 23: Transmission Disassembly (23 Of 47)

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12. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove 1st-2nd fork rod and 1st-2nd shift fork.
    Fig 24: Transmission Disassembly (24 Of 47)

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13. Remove interlock plunger and interlock pin from adapter plate.
    Fig 25: Transmission Disassembly (25 Of 47)

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14. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove reverse fork rod and reverse shift fork.
    Fig 26: Transmission Disassembly (26 Of 47)

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15. Remove check balls from adapter plate.
    Fig 27: Transmission Disassembly (27 Of 47)

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16. Remove 5th-6th control lever mounting bolts, and 5th-6th control lever from adapter plate.
    Fig 28: Transmission Disassembly (28 Of 47)

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17. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove 5th-6th fork rod and 5th-6th fork rod bracket.
    Fig 29: Transmission Disassembly (29 Of 47)

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18. Drive out retaining pin using a pin punch [6 mm (0.24 in) dia.], and remove 5th-6th fork rod (reversal side) and 5th-6th shift fork.
    Fig 30: Transmission Disassembly (30 Of 47)

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Gear Components 

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

• Main drive gear
  1. End play :0 - 0.1mm (0 - 0.004in) 
  Fig 31: Transmission Disassembly (31 Of 47)

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• Main shaft rear side
  1. End play :0 - 0.1mm (0 - 0.004in) 
  Fig 32: Transmission Disassembly (32 Of 47)

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• Counter gear
  1. End play :0 - 0.1mm (0 - 0.004in) 
  Fig 33: Transmission Disassembly (33 Of 47)

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1. After removing snap ring, remove reverse synchronizer assembly and reverse main gear from main shaft using a puller.
   1. Tool number :Commercial service tool 
2. Remove reverse main needle bearing from main shaft.
   Fig 34: Transmission Disassembly (34 Of 47)

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3. Remove main shaft bearing retainer mounting bolts and main shaft bearing retainers from adapter plate.
   Fig 35: Transmission Disassembly (35 Of 47)

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4. After removing snap ring, remove reverse counter gear and counter rear bearing spacer using a puller.
   1. Tool number :Commercial service tool 
   Fig 36: Transmission Disassembly (36 Of 47)

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5. Remove snap ring from main shaft bearing.
   Fig 37: Transmission Disassembly (37 Of 47)

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6. Remove main shaft assembly and counter shaft assembly together from adapter plate.
   Fig 38: Transmission Disassembly (38 Of 47)

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7. Remove counter rear bearing from adapter plate.
   Fig 39: Transmission Disassembly (39 Of 47)

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8. Remove main drive gear, main pilot bearing, pilot bearing spacer and 5th baulk ring from main shaft.
9. Remove snap ring from main drive gear using snap ring pliers.
   Fig 40: Transmission Disassembly (40 Of 47)

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10. Set a puller on main drive gear bearing, and remove main drive gear bearing from main drive gear using a press.
    1. Tool number :Commercial service tool 
    Fig 41: Transmission Disassembly (41 Of 47)

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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.
    1. Tool number :Commercial service tool 
    Fig 42: Transmission Disassembly (42 Of 47)

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12. Remove 3rd-4th main spacer from main shaft.
13. Set a puller on 1st main gear, and remove 3rd main gear and 1st main gear from main shaft using a press.
    1. Tool number :Commercial service tool 
    CAUTION: Be careful not to damage baulk ring.
14. Remove 1st needle bearing from main shaft.
    Fig 43: Transmission Disassembly (43 Of 47)

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15. Set a puller on 2nd main gear, and remove 1st-2nd synchronizer assembly and 2nd main gear from main shaft using a press.
    1. Tool number :Commercial service tool 
       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.
    Fig 44: Transmission Disassembly (44 Of 47)

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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.
    1. Tool number :Commercial service tool 
18. Remove 6th needle bearing from main shaft.
    Fig 45: Transmission Disassembly (45 Of 47)

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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.
    1. Tool number :Commercial service tool 
    Fig 46: Transmission Disassembly (46 Of 47)

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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.
    1. Tool number :Commercial service tool 
    Fig 47: Transmission Disassembly (47 Of 47)

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