Part 2

TL70 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: DISASSEMBLY; 2013 MY FR-S [03/2012 -] (Continued)

16. REMOVE NO. 2 SHIFT INTER LOCK PIN

(a) Remove the No. 2 shift inter lock pin from the No. 1 shift fork shaft.

17. REMOVE SHIFT AND SELECT LEVER

(a) Remove the bolt and shift and select lever from the No. 1 shift fork shaft.

18. REMOVE NO. 1 STRAIGHT SCREW PLUG

(a) Using a T40 "TORX" socket wrench, remove 3 No. 1 straight screw plugs.

(b) Using a magnet hand, remove the 2 No. 2 shift detent ball compression springs and 2 shaft detent balls.

19. REMOVE REVERSE SHIFT ARM

(a) Using a screwdriver, remove the shift arm shoe E-ring.

NOTICE:
Use a cloth to prevent the shift arm shoe E-ring from flying off.

(b) Remove the reverse shift arm.

20. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

(a) Remove the No. 4 gear shift fork shaft and reverse and 5th shift head together.

NOTICE:
* Be careful not to drop the shaft detent ball from the reverse and 5th shift head.
* The shaft detent ball on the manual transmission case may fall inside the manual transmission case. If that happens, take it out when the manual transmission case is removed.

(b) Remove the shaft detent ball from the reverse and 5th shift head.

21. REMOVE REVERSE AND 5TH SHIFT HEAD

(a) Using 2 screwdrivers and a plastic hammer, remove the shift fork shaft shaft snap ring.

NOTICE:
Use a cloth to prevent the shift fork shaft shaft snap ring from flying off.

(b) Remove the washer.

NOTICE:
Be careful of the shaft detent ball and shift detent ball compression spring that fall out when sliding the reverse and 5th shift head.

22. INSPECT COUNTER 6TH GEAR THRUST CLEARANCE

(a) Using SST and a dial indicator, measure the thrust clearance.

SST : 09350-20015

09350-06120

Standard clearance:

0.10 to 0.40 mm (0.00394 to 0.0157 in.)

Maximum clearance:

0.40 mm (0.0157 in.)

HINT
If the clearance exceeds the maximum, replace the counter 6th gear, No. 4 transmission clutch hub, 6th gear thrust washer, 6th gear needle roller bearing and counter shaft with a new ones.

23. INSPECT COUNTER 6TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000590 to 0.00268 in.)

Maximum clearance:

0.068 mm (0.00268 in.)

HINT
If the clearance exceeds the maximum, replace the counter 6th gear, 6th gear needle roller bearing and counter shaft with a new ones.

24. REMOVE NO. 4 TRANSMISSION CLUTCH HUB

(a) Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

NOTICE:
Use a cloth to prevent the shaft snap ring from flying off.

(b) Using SST and 3 bolts, remove the No. 4 transmission clutch hub, No.4 transmission hub sleeve, No. 4 gear shift fork and No. 5 gear shift fork shaft all together.

SST : 09950-30012

09951-03010

09953-03010

09956-03010

25. REMOVE NO. 4 GEAR SHIFT FORK

(a) Using a 5 mm pin punch and hammer, remove the slotted spring pin.

(b) Remove the No. 4 gear shift fork from the No. 5 gear shift fork shaft.

26. REMOVE NO. 4 TRANSMISSION HUB SLEEVE

(a) Using a screwdriver, remove the No. 4 clutch hub snap ring.

(b) Remove the No. 4 transmission hub sleeve, and then remove the 3 No. 1 synchromesh shifting keys, 3 No. 1 synchromesh shifting key springs and 3 synchromesh shifting key balls from the No. 4 transmission clutch hub.

NOTICE:
* Use a cloth to prevent the No. 1 synchromesh shifting keys, No. 1 synchromesh shifting key springs and synchromesh shifting key balls from popping out.
* Do not deform the No. 1 synchromesh shifting key spring.

HINT
During this operation, keep intact the No. 4 transmission clutch hub and No. 1 synchromesh shifting key.

27. REMOVE NO. 4 SYNCHRONIZER RING

(a) Remove the No. 4 synchronizer ring.

28. REMOVE COUNTER 6TH GEAR

(a) Remove the counter 6th gear.

29. REMOVE 6TH GEAR NEEDLE ROLLER BEARING

(a) Remove the 6th gear needle roller bearing.

30. REMOVE 6TH GEAR THRUST WASHER

(a) Remove the 6th gear thrust washer.

(b) Remove the gear thrust washer straight pin.