Manual Transmission Unit Disassembly

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING 

1. Remove clutch operating cylinder assembly from transmission front case referring to CLUTCH OPERATING CYLINDER ASSEMBLY REMOVAL AND INSTALLATION
2. Remove gear shift control lever rear cause assembly and gear shift lever front case assembly referring to GEAR SHIFT CONTROL LEVER REAR CASE ASSEMBLY REMOVAL AND INSTALLATION  and GEAR SHIFT LEVER FRONT CASE ASSEMBLY REMOVAL AND INSTALLATION .
3. Separate transfer assembly (1) or extension case from transmission assembly.
   Fig 1: Identifying Transfer Assembly

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4. Remove adapter case (1) from rear case (2).
5. Remove output shaft assembly (3) from adapter case.
   Fig 2: Identifying Adapter Case From Rear Case

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6. Remove reverse shaft bolt (1) and back up light switch (2).
   Fig 3: Identifying Reverse Shaft Bolt & Back Up Light Switch

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7. Remove gear shift locating bolts (1), then take out locating springs (2) and gear shift shaft balls (3).
8. Remove rear to front case bolts (4), then separate rear case from front case tapping front case flange with plastic hammer.
   Fig 4: Identifying Gear Shift Locating Bolts, Locating Springs & Gear Shift Shaft Balls

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9. Remove oil gutter.
10. Remove reverse shaft assembly (1).
11. Remove low gear shift inverse lever (4).
12. Remove low speed gear shift shaft (2) and 5th & reverse gear shift fork (3) with 5th speed synchronizer sleeve (5).
    Fig 5: Identifying Low Speed Gear Shift Shaft, 5th & Reverse Gear Shift Fork

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13. Remove input shaft needle bearing, 5th speed synchronizer ring and 5th speed synchronizer levers.
14. Remove input shaft front bearing circlip (1) from case using special tool.

    Special Tool 

    1. 09900-06106 
    Fig 6: Identifying Special Tool Into Input Shaft Bearing Circlip

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15. Remove input shaft assembly (1), countershaft assembly (2), high speed gear shift fork (3) and low speed gear shift fork (4) as assembly from front case (5) tapping input shaft end by plastic hammer lightly.
    Fig 7: Identifying Input Shaft Assembly & Countershaft Assembly

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