GSIC - Global Service Information Center

# MANUAL TRANSMISSION UNIT > REMOVAL

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1. REMOVE FILLER PLUG

1. Remove the filler plug and gasket from the transmission case.

2. REMOVE DRAIN PLUG

1. Remove the drain plug and gasket from the transmission case.

3. REMOVE CLUTCH RELEASE FORK

1. Remove the release fork and release bearing from the clutch housing.

4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

1. Remove the clip and release bearing from the release fork.

5. REMOVE RELEASE FORK SUPPORT

1. Remove the release fork support from the clutch housing.

6. REMOVE CLUTCH RELEASE FORK BOOT

1. Remove the clutch release fork boot from the clutch housing.

7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

1. Using SST, remove the back-up light switch and the gasket from the transmission case.

   SST
     09817-16011

8. REMOVE CLUTCH HOUSING

1. Remove the 9 bolts.

1. Using a plastic-faced hammer, tap out the clutch housing from the transmission case.

9. REMOVE RESTRICT PIN

1. Remove the 2 restrict pins from the extension housing.

10. REMOVE CONTROL SHIFT LEVER RETAINER

1. Remove the 4 bolts from the extension housing.

1. Remove the shift lever retainer and oil deflector from the extension housing.

11. REMOVE SPEEDOMETER DRIVEN GEAR

1. Remove the bolt and driven gear.

12. REMOVE SHIFT DETENT BALL

1. Using a T40 "torx" socket wrench, remove the spring seat from the extension housing.

1. Using a magnetic finger, remove the compression spring and shift detent ball from the extension housing.

13. REMOVE EXTENSION HOUSING

1. Remove the bolt from the shift lever housing.

1. Remove the 8 bolts.

1. Using a plastic-faced hammer, tap the extension housing and remove the shift lever housing and the shift and select lever from the transmission case.

14. REMOVE TRANSMISSION MAGNET

1. Remove the magnet from the extension housing.

15. REMOVE OIL RECEIVER PIPE

1. Remove the receiver pipe from the extension housing.

16. REMOVE OIL RECEIVER

1. Remove the bolt and oil receiver.

17. REMOVE REVERSE RESTRICT PIN

1. Using a T40 "torx" socket wrench, remove the plug from the extension housing.

1. Using a 5 mm pin punch and hammer, tap out the restrict slotted spring pin from the extension housing.

1. Remove the restrict pin from the extension housing.

18. REMOVE EXTENSION HOUSING OIL SEAL

1. Using a screwdriver and hammer, tap out the oil seal from the extension housing.

19. REMOVE BEARING RETAINER FRONT

1. Remove the 8 bolts.

1. w/o Gasket:
   Remove the bearing retainer from the transmission case.

1. w/ Gasket:
   Remove the bearing retainer and gasket from the transmission case.

20. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

1. Using a screwdriver, pry out the oil seal from the bearing retainer front.

21. REMOVE FRONT BEARING SHAFT SNAP RING

1. Using a snap ring expander, remove the snap ring from the transmission case.

22. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

1. Using a snap ring expander, remove the snap ring from the transmission case.

23. REMOVE MANUAL TRANSMISSION CASE

1. Stand the transmission as shown in the illustration.

1. Using a plastic-faced hammer, carefully tap off the transmission case.

1. Remove the transmission case from the intermediate plate as shown in the illustration.

24. FIX INTERMEDIATE PLATE

1. Fix the intermediate plate in a vise.

25. REMOVE SHIFT DETENT BALL

1. Using a T40 "torx" socket wrench, remove the 3 spring seats from the intermediate plate.

1. Using a magnetic finger, remove the 3 compression springs and 3 shift detent balls from the intermediate plate.

26. REMOVE NO. 2 SHIFT DETENT BALL

1. Using a T40 "torx" socket wrench, remove the spring seat from the intermediate plate.

1. Using a magnetic finger, remove the compression spring and detent ball from the intermediate plate.

27. REMOVE NO. 4 SHIFT FORK SHAFT

1. Remove the bolt from the No. 3 gear shift fork.

1. Using 2 screwdrivers and a hammer, tap out the snap ring and 2 reverse shift head rings form the No. 4 shift fork shaft.

1. Remove the No. 4 shift fork shaft, ball pin shift interlocks and No. 3 gear shift fork from the intermediate plate.

28. REMOVE NO. 5 SHIFT FORK SHAFT

1. Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the reverse shift head.

1. Remove the reverse shift head and No. 5 shift fork shaft from the intermediate plate.

29. REMOVE NO. 3 SHIFT FORK SHAFT

1. Using a magnetic finger, remove the No. 2 shift interlock pin with the No. 3 shift fork shaft.

1. Remove the shift detent ball and compression spring from the reverse shift fork.

1. Using a magnetic finger, remove the No. 3 shift interlock pin from the intermediate plate.

30. REMOVE NO. 3 HEAD GEAR SHIFT

1. Using a 5 mm pin pinch and hammer, tap out the slotted spring pin from the No. 3 shaft fork shaft.

1. Remove the No. 3 head gear shift from the No. 3 shift fork shaft.

31. REMOVE NO. 2 SHIFT INTERLOCK PIN

1. Using a magnetic finger, remove the No. 2 interlock pin from the No. 1 shift fork shaft.

32. REMOVE NO. 1 SHIFT FORK SHAFT

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 1 shift fork shaft.

1. Remove the gear bolt from the No. 1 gear shift fork.

1. Remove the No. 1 shift fork shaft from the intermediate plate.

33. REMOVE NO. 1 SHIFT INTERLOCK PIN

1. Using a magnetic finger, remove the No. 1 interlock pin from the intermediate plate.

34. REMOVE NO. 2 SHIFT FORK SHAFT

1. Remove the bolt from the No. 2 gear shift fork.

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 shift fork shaft.

1. Remove the No. 2 shift fork shaft, No. 1 gear shift fork and No. 2 gear shift fork from the intermediate plate.

35. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the thrust clearance.

   Standard clearance:
     0.125 to 0.325 mm (0.0049 to 0.0128 in.)

   Maximum clearance:
     0.325 mm (0.0128 in.)

36. REMOVE COUNTER SHAFT 5TH GEAR ASSEMBLY

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the counter gear.

1. Using SST, remove the No. 5 gear spline piece and No. 3 synchronizer ring from the counter gear.

   SST
     09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05021)

1. Remove the 5th gear and 5th gear bearing from the counter gear.

37. REMOVE 5TH GEAR THRUST WASHER

1. Remove the thrust washer from the counter gear.

1. Using a magnetic finger, remove the thrust washer lock ball from the counter gear.

38. REMOVE REVERSE SHIFT ARM BRACKET

1. Remove the 2 bolts and arm bracket with the shaft arm from the intermediate plate.

39. REMOVE REVERSE SHIFT ARM

1. Using a screwdriver, pry out the E-ring.

1. Remove the shift fork from the shift arm.

40. REMOVE REVERSE IDLER GEAR

1. Remove the bolt and idler gear shaft stopper from the intermediate plate.

1. Remove the idler gear shaft and idler gear from the intermediate plate.

41. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the radial clearance.

   Standard clearance:
     0.04 to 0.08 mm (0.0016 to 0.0031 in.)

   Maximum clearance:
     0.08 mm (0.0031 in.)
   1. If the clearance is greater than the maximum, replace the reverse idler gear.

42. INSPECT REVERSE IDLER GEAR

1. Using a feeler gauge, measure the clearance between the reverse idler gear and reverse shift arm.

   Standard clearance:
     0.05 to 0.35 mm (0.0020 to 0.0138 in.)

   Maximum clearance:
     0.35 mm (0.0138 in.)
   1. If the clearance is greater than the maximum, replace the reverse idler gear and reverse shift arm.

43. REMOVE OUTPUT SHAFT REAR BEARING RETAINER

1. Using a T40 "torx" socket wrench, remove the 4 screws and rear bearing retainer from the intermediate plate.

44. REMOVE COUNTER GEAR ASSEMBLY

1. Using a snap ring expander, remove the snap ring from the counter shaft center bearing.

1. Using SST, remove the center bearing, counter gear and input shaft from the intermediate plate.

   SST
     09950-40011 (09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04011, 09958-04011)

45. REMOVE OUTPUT SHAFT ASSEMBLY

1. Using a snap ring expander, remove the snap ring from the output center bearing.

1. Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.