Transmission Case

Special Tool(s)

	Handle 205-153 (T80T-4000-W)
	Installer, Ball Bearing 307-557
	Installer, Bushing 307-664
	Installer, Differential Seal 307-626
	Installer, Input Shaft Bearing 308-202 (T91T-7127-B)
	Pilot, Transfer Gear Roller Bearing 307-541
	Remover, Detent 308-812
	Slide Hammer 100-001 (T50T-100-A)

NOTE: Refer to the on-line Workshop Manual to view this illustration as an interactive exploded view, requires Adobe® Acrobat® 8.0 or higher.

NOTE: Refer to the on-line Workshop Manual to learn about using an Interactive Illustration.

Disassembly

1. Remove the 8 bearing retaining bolts.

2. Using the Input Shaft Bearing Installer and the Handle, remove the input shaft bearing.
   • Inspect the input shaft bearing for wear or damage. Install a new bearing as necessary.

3. Using the Input Shaft Bearing Installer and the Handle, remove the countershaft bearing.
   • Inspect the countershaft bearing for wear or damage. Install a new bearing as necessary.

4. If replacing the transmission case, remove the clutch slave cylinder tube retaining clip.

5. If replacing the transmission case, remove the transmission case vent tube.

6. Using a brass drift, tap the dowel pins flush with the transmission case.

7. Remove the reverse idler gear bracket bolt and the reverse idler gear assembly.
   • Inspect the reverse idler gear for wear or damage. Install a new gear as necessary.
   • Inspect the reverse idler gear needle bearing and shaft for wear or damage. Install new components as necessary.

8. Remove the 4 bearing retaining bolts.

9. Using the Bushing Installer and the Handle, remove the output shaft bearing.
   • Inspect the output shaft bearing for wear or damage. Install a new bearing as necessary.

10. If replacing the transmission case, use the Detent Remover and the Slide Hammer to remove the shift shaft detent.

11. If leakage is present, remove the shift shaft seal.

12. Clean and inspect the front and rear transmission cases.
    • Inspect the shift shaft and shift rail bearings for wear or damage. Install new components as necessary.
    • Inspect the rear countershaft bearing for wear or damage. Install a new rear transmission case as necessary.

Assembly

NOTICE: Lubricate all components with the recommended transmission fluid before reassembling.

1. If removed, install the shift shaft seal.

2. If removed, use a soft-faced hammer to install the shift shaft detent.

3. NOTICE: Do not heat the transmission case higher than 120°C (248°F) maximum or damage to the transmission case can occur.

   Using a heat gun, heat the transmission case to a maximum of 120°C (248°F).

4. NOTICE: Install the output shaft bearing with the grooved side of the outer output shaft bearing race facing the inside of the transmission case or damage to the transmission case can occur.

   With the grooved side of the outer output shaft bearing race facing the inside of the transmission case, use the Transfer Gear Roller Bearing Pilot and the Handle to install the output shaft bearing.

5. Install the 4 bearing retaining bolts.
   • Apply Threadlock to the bearing retaining bolts.
   • Tighten to 36 Nm (27 lb-ft).

6. Install the reverse idler gear shaft.

7. Install the reverse idler gear and the reverse idler gear needle bearing.

8. Install the reverse idler gear bracket.

9. Install the reverse idler gear bracket bolt.
   • Apply Threadlock to the reverse idler gear bracket bolt.
   • Tighten to 27 Nm (20 lb-ft).

10. NOTICE: Do not heat the transmission case higher than 120°C (248°F) maximum or damage to the transmission case can occur.

    Using a heat gun, heat the transmission case to a maximum of 120°C (248°F).

11. Using the Ball Bearing Installer and the Handle, install the countershaft bearing.

12. NOTICE: Install the input shaft bearing with the grooved side of the outer input shaft bearing race facing the inside of the transmission case or damage to the transmission case can occur.

    With the grooved side of the outer input shaft bearing race facing the inside of the transmission case, use the Differential Seal Installer and the Handle to install the input shaft bearing.

13. Install the 8 bearing retaining bolts.
    • Apply Threadlock to the bearing retaining bolts.
    • Tighten to 36 Nm (27 lb-ft).

14. NOTE: Before installation of a vent tube, using manual transmission oil, lightly coat the vent tube "O" ring.

    If removed, install the transmission case vent tube with the notch pointing to the front of the transmission case.

15. If removed, install the clutch slave cylinder tube retaining clip.