Manual Transmission

Transmission Disassembly (cont'd)

 13-17  

Special Tools Required

  • Torx bit (No.45) 5-8840-0047-0 (J-29843-8)
  • Puller body 5-8840-0013-0 and 5-8840-0014-0 (J-22888)
  • Puller legs 5-8840-0566-0 (J-22888-50)

NOTE: Place the clutch housing on two pieces of wood thick enough to keep the input shaft from hitting the workbench.

  1. Remove the rear cover assembly.
  1. Remove the control box assembly.
  1. Use a screwdriver to shift the transmission through each speed (1st gear to 4th gear). Use the 5th shift arm to shift into 5th gear (double engagement).
  1. Remove the 5th gear nut (A).

  1. Remove the sleeve and hub nut from the output shaft. Discard the fixing nuts.
  1. Return the transmission to the neutral position. Align the shift rail detent positions.
  1. Place 5th synchroniser assembly (A) in neutral. Remove the spring pin (B) at 5th shift arm (C) and discard the spring pin.

  1. Remove the 1st/2nd detent plug (A), 3rd/4th detent plug (B), 5th detent plug (C), detent springs and detent balls.

  1. Remove the insert stopper plate.
  1. Remove the 5th synchroniser assembly, 5th shift arm, 5th block ring and output 5th gear.
  1. Remove the 5th gear needle bearing.
  1. Remove the input 5th gear.
  1. Remove the seven 8 X 1.25 torx screw (A) from the transmission case bearing retainer (B), using the special tool.

  1. Remove the output shaft bearing shim and transmission case bearing retainer from the output shaft.