Manual Transmission Disassembly (M/T)

Manual Transmission Disassembly

Exploded View-Clutch Housing

5-speed model:

BACK-UP LIGHT SWITCHMAINSHAFT ASSEMBLYCOUNTERSHAFT ASSEMBLY35 x 58 x 8 mm OIL SEALREVERSE IDLER GEAR(16)(17)(18)(19)(20)(21)REVERSE LOCK CAMBALL BEARINGREVERSE GEAR SHAFT28 x 43 x 7 mm OIL SEAL(15)(1)(6)(7)(8)(9)(10)(11)(12)(13)14 x 20 mm DOWEL PINMAGNETDIFFERENTIAL ASSEMBLYOIL GUIDE PLATE CBEARING SET PLATENEEDLE BEARING6 mm FLANGE BOLT(14)28 mm WASHER28 mm SPRING WASHER(22)6 mm SPECIAL BOLTCLUTCH HOUSINGREVERSE SHIFT FORK ASSEMBLY(2)(3)(4)(5)(1)(6)(7)(8)(9)(10)(11)(2)(3)(4)(5)(16)(17)(18)(19)(20)(21)(15)(12)(13)(14)(22)(17)(8)(8)SHIFT FORK ASSEMBLY12 N·m (1.2 kgf·m, 9 lbf·ft)Replace.15 N·m (1.5 kgf·m, 11 lbf·ft)Replace.29 N·m (3.0 kgf·m, 22 lbf·ft)

6-speed model:

BACK-UP LIGHT SWITCHMAINSHAFT ASSEMBLYCOUNTERSHAFT ASSEMBLY35 x 58 x 8 mm OIL SEALREVERSE IDLER GEAR(16)(17)(18)(19)(20)(21)BALL BEARINGREVERSE GEAR SHAFT28 x 43 x 7 mm OIL SEAL(15)(1)(6)(7)(8)(9)(10)(11)(12)(13)14 x 20 mm DOWEL PINMAGNETDIFFERENTIAL ASSEMBLYOIL GUIDE PLATE CBEARING SET PLATENEEDLE BEARING6 mm FLANGE BOLT(14)28 mm WASHER28 mm SPRING WASHER6 mm SPECIAL BOLTCLUTCH HOUSINGREVERSE SHIFT FORK ASSEMBLY(2)(3)(4)(5)(1)(6)(7)(8)(9)(10)(11)(2)(3)(4)(5)(16)(17)(18)(19)(20)(21)(15)(12)(13)(14)(8)(8)SHIFT FORK ASSEMBLY12 N·m (1.2 kgf·m, 9 lbf·ft)Replace.15 N·m (1.5 kgf·m, 11 lbf·ft)Replace.29 N·m (3.0 kgf·m, 22 lbf·ft)

Exploded View-Transmission Housing

5-speed model:

TRANSMISSION HOUSING(25)(1)(2)(3)(5)(6)(7)(12)(15)(16)(17)(23)(1)(2)(3)(4)(5)(6)(7)32 mm SEALING CAP
34 N·m (3.5 kgf·m, 25 lbf·ft)10 mm WASHER
Replace.FILLER PLUG
44 N·m (4.5 kgf·m, 33 lbf·ft)40 x 56 x 8 mm OIL SEAL
Replace.(8)10 mm FLANGE BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)14 mm WASHER
Replace.(17)TRANSMISSION HANGER A(22)(21)(20)(19)(4)(18)(11)(10)(4)(8)(9)(14)(15)(16)(17)8 mm FLANGE BOLT
27 N·m (2.8 kgf·m, 20 lbf·ft)INTERLOCK BOLT
39 N·m (4.0 kgf·m, 29 lbf·ft)OIL GUIDE PLATE M72 mm SHIM(9)OIL GUTTER PLATEDRAIN PLUG
39 N·m (4.0 kgf·m, 29 lbf·ft)20 mm WASHER
Replace.(18)STEEL BALL(15)(16)(17)SPRINGTRANSMISSION HANGER BDETENT BOLT
22 N·m (2.2 kgf·m, 16 lbf·ft)12 mm WASHER
Replace.(24)(19)HARNESS BRACKET A(20)(21)(22)(23)(24)(25)(13)(12)(11)6 x 30 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)8 x 14 mm DOWEL PINCHANGE LEVER ASSEMBLY(10)80 mm SHIM(11)(26)(27)(28)(29)(30)(31)(32)(33)(34)TRANSMISSION HANGERHARNESS BRACKET B10 mm FLANGE BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)20 mm BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)20 mm WASHER
Replace.COUNTERSHAFT SPEED SENSORO-RING
Replace.PLAIN WASHER(26)(27)(28)(29)(30)(31)(32)(33)(34)(4)(13)(14)6 x 20 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)(35)6 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)(35)(14)(16)(18)(18)

6-speed model:

NOTE:

Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
6-speed model is shown, 5-speed model is similar.

1.	Remove the detent bolts (A), springs, steel balls and back-up light switch (B). ABCDE

2.	Remove the transmission hanger (C), 20 mm bolt (D), and 20 mm washer (E).

3.	Remove the interlock bolt (B), change lever assembly (C), 8 x 14 mm dowel pins (D), and harness bracket A. CADDB

4.	Remove the drain plug (A), filler plug (B), and 10 mm flange bolt (C). BACEFD

5.	Remove the countershaft speed sensor (D), plain washer (E), and O-ring (F).

6.	Remove the 8 mm flange bolts in a crisscross pattern in several steps.

7.	Remove the transmission hanger A, transmission hanger B, and harness bracket B (C). BCA

8.	Remove the 32 mm sealing cap (A). ABCDDD

9.	Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.

10.	Remove the transmission housing (C) and 14 x 20 mm dowel pins (D).

11.	Remove the reverse lock cam (5-speed model only).

12.	Remove the reverse idler gear (A) and reverse gear shaft (B). BA

13.	Remove the reverse shift fork.

14.	Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (C) from the clutch housing (D). BADCFE

15.	Remove the 28 mm spring washer (E) and 28 mm washer (F).

16.	Remove the differential assembly (A) and magnet (B). BA

17.	Remove the oil gutter plate (A), 72 mm shim (B), and oil guide plate M. ABM