Procedure 1 - 19

GEARS





SHIFT FORKS





CASE AND MISC. COMPONENTS

Disassembly





1. Remove the drain plug and filler plug.
a. Remove the drain plug (1) and gasket.
b. Remove the filler plug (2) and gasket.





2. Remove the clutch release bearing and shift fork.
a. Remove the clutch release bearing (3) from the front cover.
b. Remove the split pin (4). Remove the shaft from the under. Remove the shift fork (5).





3. Remove the switch.
a. Remove backup light switch (6) and gasket.
b. Remove 1st and 2nd switch (8) and gasket.
4. Remove the clutch housing.





a. Remove the 9 bolts.





b. Using a plastic hammer, carefully tap the clutch housing.





5. Remove gear control box and gasket.
a. Remove the 6 bolts, gear control box and gasket.
6. Remove transfer adapter.





a. Using a hexagon wrench, remove the plug (1).





b. Using a pin punch and hammer, drive out the slotted spring pin (2).





c. Using the M8 X 1.25 bolt, remove the gear control rod and the shift lever housing.

Note: Turn the M8 bolt a few times, before remove the gear control rod.





d. Remove the 10 bolts and clamp.





e. Using a plastic hammer, tap the transfer adapter.

Note:
^ Be careful not to lose the pin.
^ Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.

7. Disassemble the transfer adapter assembly.





a Using a torx socket wrench (T40), remove the plug.





b. Using a pin punch and hammer, drive out the slotted spring pin. Remove the reverse restrict pin.





c. Remove the oil receiver pipe.
d. Remove the oil seal.





e. Using socket hexagon wrench, remove the plug.
8. Remove the front cover.





a. Remove the 8 bolts.





b Using a plastic hammer, carefully tap the front cover.
9. Remove the front cover oil seal.
a. Mount the front cover through the aluminum plate in a vise.





b. Using screwdriver, remove oil seal (1).
10. Remove the transmission case.





a. Using a snap ring expander, remove the 2 snap rings (1), (2).





b. Using a plastic hammer, carefully tap the transmission case.
11. Mount the intermediate plate.





a. Mount the intermediate plate through the aluminum plate in a vise.
12. Remove the slotted spring pin.





a. Using a pin punch and hammer, drive out the pin from the arm.
13. Remove the shift arm set bolt.





a. Remove the 2 bolts from the shift arm.
14. Remove the counter 5th gear.





a. Using 2 screwdrivers and hammer, tap out the snap ring.





b. Using remover J-42794 and attachment J-42988, remove the 5th gear spline piece.





c. Remove the hub sleeve No. 3, block ring set, counter 5th gear, bearing and 5th shift arm.





d. Remove the synchronizer pull ring, synchronizer cone ring, and synchronizer outer ring from hub sleeve No. 3.





e. Remove the reverse block ring from the hub sleeve No. 3. Remove the 3 inserts and 3 compression springs.
15. Remove the thrust washer.
a. Remove the thrust washer from counter gear shaft.





b. Remove the thrust washer pin from counter gear shaft.
16. Remove the bearing plate.





a. Remove the 4 bolts and bearing retainer.
17. Remove the reverse idle gear.





a. Pull out the shaft forward the rear and remove the reverse idle gear.
18. Remove the counter gear shaft.





a. Using snap ring plier, remove counter gear shaft center bearing snap ring.





b. Using remover J-42795 and attachment J-42988, remove counter gear shaft center bearing.

Note: Be careful not to drop the counter gear, when removing the bearing.





c. Remove the counter gear from intermediate plate.
19. Disassemble the counter gear shaft assembly.





a. Using snap ring pliers, remove the counter gear shaft front bearing snap ring.





b. Using bearing separator J-22912-01 and a press, remove the bearing.