Steps 20-24

Disassembly
20. Remove the top gear shaft.





a. Remove the top gear shaft from mainshaft.

Note: Don't fall needle roller bearing.





b. Remove the 4th block ring and roller bearing.
21. Disassemble the top gear shaft assembly.





a. Check for wear or damage.





b. Remove the front bearing shaft snap ring.





c. Using bearing separator J-22912-01 and a press, remove the bearing.
22. Remove the mainshaft.





a. Remove mainshaft bearing snap ring.





b. Using a plastic hammer, tap the 5th-reverse shift rod at the reverse shift side.
c. Remove the intermediate plate from a vise.





d. Remove the mainshaft, 1st-2nd shift arm and 3rd-4th shift arm.
23. Disassemble the main shaft assembly.
a. Inspect each gear thrust clearance.





1. Using thickness gauge, inspect thrust clearance (1st gear, 3rd gear).
2. Mount the mainshaft through the aluminum plate in a vise.








3. Using a dial indicator, measure each gear thrust clearance.
b. Inspect each gear radial clearance








1. Using a dial indicator, measure the radial clearance of each gear.





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





d. Using bearing separator J-22912-01 and a press, remove the following parts.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).





e. Remove following parts from mainshaft.
1. Synchronizer assembly (1).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).





f. Using 2 screwdrivers and hammer, tap out snap ring.





g. Using bearing separator J-22912-01 and a press, remove the following parts.
1. Clutch hub No. 1 assembly (1).
2. Synchronizer assembly (2).
3. 2nd gear (3).
4. 2nd gear needle roller bearing (4).
h. Remove the reverse gear from clutch hub No. 1.





i. Remove the 3 inserts and 3 compression springs.
^ When removing the inserts, push the insert spring with a screwdriver.





j. Remove the snap ring.

Note: Don't damage the bearing surface.





k. Using a press, remove following parts.
1. Clutch hub No. 2 assembly (1).
2. 3rd block ring (2).
3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).





l. Using screwdriver, remove the 2 insert springs, hub sleeve No. 2, clutch hub No. 2 and 3 inserts.
24. Remove the shift parts and interlock parts.
a. Mount the intermediate plate through the aluminum plate in a vise.





b. Using a plastic hammer, tap the 5th shift rod on the neutral.





c. Using a torx socket wrench (T40), remove the 4 plugs.





d. Using a magnetic finger, remove 3 springs and balls.





e. Using 2 screwdrivers and a hammer, remove 2 snap rings from each shift fork rod.





f. Pull out the 3rd-4th shift rod at the rear.





g. Using a magnetic finger, remove the interlock pin and straight pin.





h. Pull out the 1st-2nd shift rod at the rear.





i. Using a magnetic finger, remove the interlock pin.





j. Using 2 screwdrivers and a hammer, remove 2 snap rings.





k. Pull out the 5th-reverse shift rod at the front.





l. Using a magnetic finger, remove the interlock pin from the intermediate plate. Remove the ball from the reverse shift arm No. 1.





m. Pull out at the rear reverse shift rod, reverse shift arm No. 1 and reverse shift arm No. 2 at the same time.





n. Pull out reverse shift rod from reverse shift arm No. 1.

Note: Be sure remove at the rear.





o. Using a magnetic finger, remove the ball and spring from reverse shift arm No. 1.





p. Remove the reverse shift arm No. 2 E-ring. Remove the reverse shift arm No. 2 from reverse shift arm No. 1.





q. Remove the 2 bolts and reverse shift arm bracket.