Disassembly

Transmission Disassembly





Exploded View-Clutch Housing: 2WD Model





Exploded View-Clutch Housing: 4WD Model





Exploded View-Transmission Housing

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








1. 2WD model: Remove the side cover (A) and O-ring (B). 4WD model: Remove the transfer assembly (C), O-ring (D), and 10 x 20 mm dowel pin (E).





2. Remove the detent bolts, springs, and steel balls (A), the back-up light switch (B), and the transmission hanger (C).





3. Remove the 20 mm bolt (A) and 20 mm washer (B).





4. Remove the change lever assembly (A), the 8 x 14 mm dowel pins (B), and the interlock bolt (C).





5. Remove the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C).
6. Remove the countershaft speed sensor (D), the plain washer (E), and the O-ring (F).
7. Remove the 8 mm flange bolts in a crisscross pattern in several steps.





8. Remove transmission hanger A and transmission hanger B.





9. Remove the 32 mm sealing cap (A).
10. Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
11. Remove the transmission housing (C) and 14 x 20 mm dowel pins (D).





12. Remove the reverse lock cam.





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





14. Remove the reverse shift fork.





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





17. Remove the differential assembly (A) and magnet (B).





18. Remove the oil gutter plate (A), the 72 mm shim (B), and the oil Guide orate M.