Transmission Disassembly

Transmission Disassembly

Manual Transmission Clutch Housing V6-3.5L:

Manual Transmission Housing V6-3.5L:

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

1. Remove the strainer cover (A), O-ring (B), strainer set spring (C), and oil pump strainer (D).





2. Remove the reverse lockout solenoid (A), and back up light switch (B).





3. Remove the set screws (A), 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), oil filler plug (F), and sealing washer (G).





4. Remove the set screws (A), 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and O-rings (G).





5. Remove the oil check bolt (A), 6 mm sealing washer (B), drain plug (C), and 14 mm sealing washer (D).





6. Remove transmission hanger A, transmission hanger B, clutch line bracket (C) and 8 x 16 mm flange bolt (D), and 10 x 20 mm flange bolt (E). Loosen the 10 x 40 mm flange bolts in a crisscross pattern in several steps, then remove them.





7. Remove the transmission case cap (A) and the 37.7 mm O-ring (B).





8. Expand the 75 mm snap ring (C) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
9. Remove the transmission housing (D) and the three 14 x 20 mm dowel pins (E).
10. Remove oil guide pipe A, oil guide pipe B, and the magnet (C).





11. Remove the 8 x 50 mm pin (A) and reverse shift lever (B).





12. Remove the 20 mm thrust washers (A), 20 mm thrust needle bearings (B), reverse idler gear shaft assembly (C), 33 mm spring washer (D), and reverse shift fork (E) as an assembly.





13. Remove the 8 x 50 mm pin (A), select return spring (B), shift piece shaft (C), shift piece (D) and interlock (E).





14. Remove the 5 mm spring pin, 3 mm spring pin (A), select arm (B), 14 x 20 x 5 mm dust seal (C), and select lever (D).





15. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).





16. Remove the 64 mm spring washer (E).
17. Remove the oil pump shaft (A) and differential assembly (B).





18. Remove the oil pump plate (A), oil pump inner rotor (B), and the oil pump outer rotor (C).





19. Remove the 82 mm shim (A) from the transmission housing (B).





20. Remove the 8 mm special bolt (A), 8 mm spring washer (B), shift arm (C), shift lever (D), and 16 x 23 x 5 mm dust seal (E).