Manual Transmission Disassembly and Reassembly (Except K20C1 (M/T))

Manual Transmission Disassembly and Reassembly

Special Tools Required

Image	Description/Tool Number
	Bearing Driver Attachment, 42 x 47 mm 07746-0010300
	Bearing Driver Attachment, 62 x 68 mm 07746-0010500
	Driver Handle, 15 x 135L 07749-0010000
	Oil Seal Driver, 65 mm 07JAD-PL9A100
	Snap Ring Pliers 07LGC-0010100
	Adjustable Bearing Puller, 45?75 mm 07YAC-0010102

NOTE:

Where icon is shown, click for further information.

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

Replace

	Detailed information, notes, and precautions
	Replace

	Detailed information, notes, and precautions
	Replace
*1	1.5 L Engine

1.	Detent Bolt - Remove

2.	26.0 mm Detent Ball Spring - Remove

3.	7.94 mm Steel Ball - Remove

4.	Detent Bolt - Remove

5.	23.4 mm Detent Ball Spring - Remove

6.	7.94 mm Steel Ball - Remove

7.	Breather Cap - Remove

8.	Change Lever Assembly - Remove

9.	Detent Bolt - Remove

10.	26.0 mm Detent Ball Spring - Remove

11.	7.94 mm Steel Ball - Remove

12.	Transmission Hanger C - Remove

13.	Filler Plug - Remove

14.	Back-Up Light Switch - Remove

15.	Output Shaft (Countershaft) Speed Sensor - Remove

16.	Neutral Position Sensor - Remove

17.	Detent Bolt - Remove

18.	26.0 mm Detent Ball Spring - Remove

19.	7.94 mm Steel Ball - Remove

20.	Oil Check Bolt - Remove

21.	8 mm Flange Bolt - Remove

22.	Drain Plug - Remove

23.	32 mm Sealing Cap - Remove

24.	8 mm Flange Bolt - Loosen

NOTE: Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them.

25.	Clutch Line Bracket - Remove

26.	Transmission Hanger B - Remove

27.	Transmission Housing - Remove

While expanding the 72 mm snap ring (A) on the countershaft ball bearing with the snap ring pliers, lift the transmission housing (B). Release the snap ring pliers, and remove the transmission housing with the 14 x 20 mm dowel pins (C).

28.	Oil Seal - Remove

NOTE: Be careful not to damage the transmission housing while removing the oil seal.

29.	Oil Guide Plate M - Remove

30.	72 mm Shim - Remove

31.	Oil Gutter Plate A - Remove

32.	Oil Gutter Plate B - Remove

33.	90 mm Shim - Remove

34.	72 mm Snap Ring - Remove

35.	Oil Guide Plate C - Remove

36.	Reverse Shift Holder - Remove

37.	Baffle Plate - Remove

38.	Reverse Idler Gear Shaft Assembly/Reverse Shift Fork - Remove

Remove the reverse idler gear shaft assembly (A), the 33 mm spring washer (B), the thrust washer (C), and the reverse shift fork (D) as an assembly.

39.	Shift Piece Shaft - Remove

40.	Shift Piece - Remove

41.	Interlock - Remove

42.	Select Return Spring - Remove

43.	Shift Piece Collar - Remove

44.	8 x 50 mm Pin - Remove

45.	Mainshaft, Countershaft, and Shift Fork Assembly - Remove

Apply a thin layer of tape to the mainshaft splines (A) to protect the oil seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

Remove the mainshaft assembly (B) and the countershaft assembly (C) with the shift fork assembly (D).

46.	64 mm Spring Washer - Remove

47.	Mainshaft Oil Seal - Remove

NOTE: Be careful not to damage the clutch housing while removing the mainshaft oil seal.

48.	Bearing Set Plate - Remove

49.	Countershaft Bearing - Remove

Remove the bearing (A) using the 45?75 mm adjustable bearing puller and a commercially available 3/8''-16 UNF slide hammer (B).

50.	Differential Assembly - Remove

51.	Magnet - Remove

NOTE: Clean the magnet and the clutch housing.

52.	Oil Gutter Plate C - Remove (1.5 L Engine)

53.	Oil Seal - Remove

NOTE: Be careful not to damage the clutch housing while removing the oil seal.

NOTE:

Where icon is shown, click for further information.

Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces and the O-rings.

When applying liquid gasket, clean any dirt and oil off from the sealing surfaces.

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

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace
*1	1.5 L Engine

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace

1.	Oil Seal - Install

Install the oil seal flush with the clutch housing using the 65 mm oil seal driver.

2.	Oil Gutter Plate C - Install (1.5 L Engine)

3.	Magnet - Install

4.	Differential Assembly - Install

5.	Countershaft Bearing - Install

Install the bearing using the 15 x 135L driver handle and the 62 x 68 mm bearing driver attachment.

6.	Bearing Set Plate - Install

7.	Mainshaft Oil Seal - Install

Install the oil seal flush with the clutch housing using the 15 x 135L driver handle and the 42 x 47 mm bearing driver attachment.

Oil Seal Installed Height:

1.0?1.4 mm (0.039?0.055 in)

8.	64 mm Spring Washer - Install

NOTE: Be sure to install the spring washer in the direction shown.

9.	Mainshaft, Countershaft, and Shift Fork Assembly - Install

Apply a thin layer of tape to the mainshaft splines (A) to protect the oil seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

Install the mainshaft (B) and the countershaft (C) with the shift fork assembly (D) as an assembly.

10.	Shift Piece Assembly (Shift Piece Shaft, Shift Piece, Interlock, Select Return Spring, Shift piece Collar, 8 x 50 mm Pin) - Install

11.	Reverse Idler Gear Shaft Assembly - Install

Assemble the reverse idler gear shaft assembly (A), the reverse shift fork (B), the 33 mm spring washer (C) and the 20 mm thrust washer (D).

NOTE: Be sure to install the spring washer in the direction shown.

Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing.

Align the mark (A) on the clutch housing with the reverse gear holder hole (B).

12.	Baffle Plate - Install

Set the baffle plate (A) into the reverse gear holder hole (B).

13.	Reverse Shift Holder - Install

14.	Oil Seal - Install

Install the oil seal flush with the transmission housing using the 65 mm oil seal driver.

15.	Oil Guide Plate C - Install

16.	72 mm Snap Ring - Install

17.	Proper Size 90 mm Shim - Select

18.	90 mm Shim - Install

19.	Oil Gutter Plate B - Install

20.	Oil Guide Plate M - Install

21.	Proper Size 72 mm Shim - Select

22.	72 mm Shim - Install

23.	Oil Gutter Plate A - Install

24.	Transmission Housing - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

Install the 14 x 20 mm dowel pins (A).

Place the transmission housing on the clutch housing, making sure to line up the shafts.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing using the snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the snap ring pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the snap ring groove of the countershaft ball bearing.

Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension

as installed:

3.3?6.0 mm(0.130?0.236 in)

Make sure oil guide plate C is positioned on the transmission housing as shown.

25.	Clutch Line Bracket - Loosely Install

26.	Transmission Hanger B - Loosely Install

27.	Transmission Housing Bolt - Tighten

Install the 8 mm flange bolts finger-tight.

Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

28.	32 mm Sealing Cap - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

29.	Drain Plug - Install

30.	8 mm Flange Bolt - Install

31.	7.94 mm Steel Ball - Install

32.	26.0 mm Detent Ball Spring - Install

33.	Detent Bolt - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

34.	Oil Check Bolt - Install

35.	Output Shaft (Countershaft) Speed Sensor - Install

36.	Neutral Position Sensor - Install

37.	Back-Up Light Switch - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

38.	7.94 mm Steel Ball - Install

39.	26.0 mm Detent Ball Spring - Install

40.	Detent Bolt - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

41.	Transmission Hanger C - Install

42.	Filler Plug - Loosely Install

43.	Change Lever Assembly - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

Install the 8 x 10 mm dowel pins and the change lever assembly.

44.	Breather Cap - Install

NOTE: Turn the breather cap mark toward the front side of the vehicle.

45.	7.94 mm Steel Ball - Install

46.	26.0 mm Detent Ball Spring - Install

47.	Detent Bolt - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

48.	7.94 mm Steel Ball - Install

49.	23.4 mm Detent Ball Spring - Install

50.	Detent Bolt - Install

NOTE: Do the following procedure whenever installing the parts.

Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

51.	Transmission Gear - Check

Check that the transmission shifts into all gears smoothly.