Part 1

MANUAL TRANSMISSION UNIT ASSY (R155/R155F)























COMPONENTS

OVERHAUL





1. REMOVE MANUAL TRANSMISSION FILLER PLUG
a. Remove the transmission filler plug and gasket from the transmission case.





2. REMOVE DRAIN (MTM) PLUG SUB-ASSY
a. Remove the transmission drain plug and gasket from the transmission case.





3. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork and clutch release bearing from the clutch housing.





4. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the release bearing hub clip, and then remove the clutch release bearing from the clutch release fork.





5. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the clutch housing.





6. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the clutch housing.





7. REMOVE CLUTCH HOUSING
a. Remove the 9 bolts.





b. Using a plastic hammer, remove the clutch housing from the transmission case.





8. REMOVE BACK UP LAMP SWITCH ASSY
a. Using SST, remove the back-up lamp switch assy and the gasket from the transmission case.
SST 09817-16011
9. REMOVE SPEEDOMETER SENSOR (R155 TRANSMISSION)
a. Remove the bolt and speedometer sensor from the extension housing.
b. Remove the O-ring from the speedometer sensor.





10. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSY (R155 TRANSMISSION)
a. Remove the 6 bolts.
b. Remove the floor shift control shift lever retainer gasket from the extension housing.
c. Remove the control shift lever retainer gasket from the extension housing.





11. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSY (R155F TRANSMISSION)
a. Remove the 4 bolts.
b. Remove the floor shift control shift lever retainer from the transfer adapter.
c. Remove the oil deflector from the transfer adapter.





12. REMOVE REVERSE RESTRICT PIN
a. Remove the 2 reverse restrict pins from the extension housing or transfer adapter.





13. REMOVE EXTENSION (MTM) HOUSING SUB-ASSY (R155 TRANSMISSION)
a. Remove the shift lever housing set bolt from the shift lever housing.





b. Remove the 10 bolts.
c. Using a plastic hammer, remove the extension housing, shift lever housing and shift and select lever.





14. REMOVE TRANSFER ADAPTER (R155F TRANSMISSION)
a. Remove the shift lever housing set bolt.





b. Remove the 10 bolts.
c. Using a plastic hammer, remove the adapter, shift lever housing and shift and select lever from the transmission case.





15. REMOVE OIL RECEIVER
a. Remove the oil receiver from the extension housing (R155) or transfer adapter (R155F).
16. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE (R155 TRANSMISSION)
a. Remove the bolt and oil receiver pipe from the extension housing.
17. REMOVE REVERSE RESTRICT PIN ASSY
a. Using a Torx socket wrench T40, remove the reverse restrict pin plug from the transfer adapter.





b. Using a pin punch (5 mm) and a hammer, remove the reverse restrict pin slotted from the transfer adapter or extension housing.





c. Remove the reverse restrict pin from the transfer adapter or extension housing.





18. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL (R155 TRANSMISSION)
a. Using a screwdriver, remove the extension housing oil seal from the extension housing.
19. REMOVE TRANSFER ADAPTER OIL SEAL (R155F TRANSMISSION)
a. Using a screwdriver, remove the transfer adapter oil seal from the transfer adapter.





20. REMOVE BEARING RETAINER FRONT (MTM)
a. Remove the 8 bolts.





b. Using a brass bar and a hammer, remove the front bearing retainer from the transmission case.





21. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL
a. Fix the front bearing retainer in a vise, between aluminum plate.
b. Using SST, remove the transmission front bearing retainer oil seal.
SST 09308-00010





22. REMOVE FRONT BEARING SHAFT SNAP RING
a. Using a snap ring expander, remove the front bearing shaft snap ring from the transmission case.





23. REMOVE COUNTER GEAR FRONT BEARING SNAP RING NO.1
a. Using a snap ring expander, remove the counter gear front bearing snap ring No.1 from the transmission case.





24. REMOVE MANUAL TRANSMISSION CASE
a. Using a brass bar and a hammer, remove the transmission case from the intermediate plate.





25. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the intermediate plate.





26. FIX INTERMEDIATE PLATE
a. Fix the intermediate plate in a vice between aluminum plates.





27. REMOVE SHIFT DETENT BALL SPRING SEAT NO.1
a. Using a Torx socket wrench T40, remove the shift detent ball spring seat No.1 from the intermediate plate.





b. Using a magnetic finger, remove the shift detent ball low side compression spring and the shift detent ball from the intermediate plate.





c. Using a Torx-socket wrench T40, remove the 3 shift detent ball spring seats No.1 from the intermediate plate.





d. Using a magnetic finger, remove the 2 shift detent ball low side compression springs and the 2 shift detent balls from the intermediate plate.





28. REMOVE GEAR SHIFT FORK SHAFT NO.2
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.2.

NOTICE: Use a shop rag to prevent the snap ring from flying off.





b. Remove the shift fork set bolt from the gear shift fork No.2.





c. Remove the gear shift fork shaft No.2 from the intermediate plate.





d. Remove the gear shift fork No.2 from the transmission hub sleeve No.2.





e. Using a magnetic finger, remove the shift interlock No.1 roller and the shift interlock pin (ball) from the intermediate plate.





29. REMOVE GEAR SHIFT FORK SHAFT NO.1
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.1.

NOTICE: Use a shop rag to prevent the snap ring from flying off.





b. Remove the shift fork set bolt from the gear shift fork No.1.





c. Remove the gear shift fork shaft No.1 from the intermediate plate.





d. Remove the gear shift fork No.1 from the reverse gear.





e. Using a magnetic finger, remove the shift interlock No.1 roller from the intermediate plate.





30. REMOVE REVERSE SHIFT FORK SHAFT
a. Using a pin punch (5 mm) and a hammer, remove the shift fork set slotted spring pin from the gear shift fork No.3.





b. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the reverse shift fork shaft.

NOTICE: Use a shop rag to prevent the snap ring from flying off.





c. Remove the gear shift fork No.3 and reverse shift fork shaft from the intermediate plate.





d. Using a magnetic finger, remove the shift interlock No.1 roller from the intermediate plate.





e. Using a magnetic finger, remove the reverse shift fork ball from the reverse shift fork.





31. REMOVE 5TH SHIFT ARM SHAFT
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the 5th shift arm shaft.

NOTICE: Use a shop rag to prevent the snap ring from flying off.





b. Remove the 5th shift arm shaft from the intermediate plate.

NOTICE: Cover the hole with a shop rag to prevent the reverse shift fork ball from popping out.





c. Using a magnetic finger, remove the reverse shift fork return compression spring from the reverse shift fork.





32. REMOVE REVERSE SHIFT FORK
a. Remove the reverse shift fork together with the reverse shift arm from the intermediate plate.





b. Using a screwdriver, remove the reverse shift arm end shaft ring and the reverse shift fork from the reverse shift arm.





33. REMOVE REVERSE SHIFT ARM BRACKET
a. Remove the 2 bolts and reverse shift arm bracket from the intermediate plate.