Spark

Transmission Disassemble

Special Tools

For equivalent regional tools, refer to Special Tools

1. Remove the manual transmission. Refer to Transmission Replacement .
2. Remove the clutch release arm. Refer to Clutch Pedal Arm Replacement .
3. Remove the clutch release bearing, shaft, and bushing. Refer to Clutch Release Bearing Replacement .



4. Remove the clutch cable bracket bolts (1) and bracket (2).



5. Remove the selector and gear lever cable bracket bolts (1) and washers (2).
6. Remove the selector and gear lever cable bracket (3) and bush (4).



7. Remove the reverse light switch (1).
8. Remove the speedometer driven gear assembly bolt (2).
9. Remove the speedometer driven gear assembly (3).



10. Remove 8 side cover bolts (1).
11. Remove side cover (2) using a rubber hammer.
12. Remove the sealant on the side cover and the transmission case.



13. Remove the input shaft circlip (1).
14. Remove the 5th gear synchroniser hub plate (2).



15. Remove the 5th gear selector fork pin (1) using a pin punch and a hammer.



16. Pull and remove the input shaft 5th gear fork (1) and the synchroniser hub assembly (2) together.
17. Remove the synchroniser ring, levers and sleeve from the 5th synchroniser hub assembly.



18. Pull and remove the input shaft 5th gear (1).
19. Remove the input shaft 5th gear bearing (2).



20. Move the shift shaft lever into the 4th gear position.
21. Hold the input shaft using the DT-49084 input shaft holder (1).
22. Remove the caulking and the layshaft 5th gear nut (2).



23. Remove the layshaft 5 gear (1).



24. Remove 6 left case plate screws (1).
25. Remove the left case plate (2).
26. Remove the layshaft bearing shim (3).



27. Remove the 1st-2nd gear shift shaft ball, spring, washer and bolt (1).
28. Remove the 3rd-4th gear shift shaft ball, spring, washer and bolt (2).




Note: The case (Left) cannot be removed without removing the reverse idle gear shaft bolt.

29. Remove the reverse idle gear shaft bolt (1).



30. Remove the bolts (1) from the right case side.



31. Remove 12 bolts (1) from the left case side.
32. Remove the left side case by hitting with a rubber hammer lightly.
33. Remove the sealant on the case.



34. Remove the bolts (1).
35. Remove the reverse gear gear lever (2).



36. Push the reverse idle gear toward the inner case.
37. Pull shaft and remove the reverse idle gear (2) and shaft (1).
38. Remove the reverse idle gear (2) from the shaft assembly.




Note: Remove the shift interlock bolt. Otherwise, gear shift and shaft assembly cannot be removed.

39. Remove the shift interlock washer (2) and bolt (1).



40. Remove the 5th and reverse gear shift shaft ball, spring, washer and bolt (1)
41. Remove the 5th and reverse gear shift shaft (2).



42. Remove the shift and select lever inner and outer pins (1).



43. Remove the shift and select shaft (1).
44. Remove the gear select spring assembly (2).
45. Remove the gear shift interlock plate (3).
46. Remove the gear lever (4).
47. Remove the gear selector spring assembly (5).
48. Remove the 5th and reverse gear shift cam (6).
49. Remove the return spring (7).
50. Remove the shifter and selector bellows (8).
51. Remove the shift and selector shaft oil seal (9).




Note: Be careful not to damage the teeth of the layshaft pinion and differential ring gear.

52. Remove the gear unit and the shift shaft assembly (1) together.
53. Remove the high and the low speed shift shaft assembly from the gear unit.



54. Insert a wooden levering device (1) into the lower side of the differential.
55. Remove the differential assembly (2) by moving it right and left.



56. Remove the shift and select shaft needle bearings using the DT-49082 needle bearing removal/installation tool (1).



57. Remove the oil gutter (1).
58. Remove the differential left side oil seal (2) using a hammer and a copper chisel.



59. Remove the layshaft bearing outer race (2) using the DT-46496 gear, bearing installation tool (1), and hammer.



60. Remove the differential right side oil seal (1) using a hammer and a copper chisel
61. Remove the input shaft oil seal (2) using a screwdriver.