Page 2337 of 3171
MT-20
TRANSMISSION ASSEMBLY
1. Control housing 2. Gasket 3. Plunger
4. Park/neutral position (PNP) switch 5. Clip 6. Back-up lamp switch
7. Sliding ball bearing 8. Bushing 9. Rear extension oil gutter
10. Cap 11. Counter end bearing 12. Rear extension
13. Rear oil seal 14. Dust seal 15. Dowel pin
16. OD gear case
A: Seal lip
: 2WD models : 4WD models
Refer toGI-10, "
Components"and the followings for the symbols in the figure.
: Apply Genuine Liquid Gasket, Three Bond TB1215 or the equivalent.
: Apply gear oil.
: Apply multi-purpose grease.
PCIB1656E
Page 2338 of 3171

TRANSMISSION ASSEMBLY
MT-21
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Gear Components
1. Snap ring 2. Main drive gear bearing 3. Main drive gear
4. Main pilot bearing 5. Pilot bearing spacer 6. 5th baulk ring
7. 5th-6th spread spring 8. 5th-6th shifting insert 9. 5th-6th synchronizer hub
10. 5th-6th coupling sleeve 11. 6th baulk ring 12. 6th needle bearing
13. 6th main gear 14. Mainshaft 15. 2nd needle bearing
16. 2nd main gear 17. 2nd inner baulk ring 18. 2nd synchronizer cone
19. 2nd outer baulk ring 20. 1st-2nd spread spring 21. 1st-2nd shifting insert
22. 1st-2nd synchronizer hub 23. 1st-2nd coupling sleeve 24. 1st outer baulk ring
25. 1st synchronizer cone 26. 1st inner baulk ring 27. 1st gear bushing
28. 1st needle bearing 29. 1st main gear 30. 3rd main gear
31. 3rd-4th main spacer 32. 4th main gear 33. Mainshaft bearing
34. Reverse main gear bushing 35. Reverse main needle bearing 36. Reverse main gear
37. Reverse baulk ring 38. Reverse spread spring 39. Reverse shifting insert
40. Reverse synchronizer hub 41. Reverse coupling sleeve
PCIB1616E
Page 2339 of 3171
MT-22
TRANSMISSION ASSEMBLY
1. Counter front bearing 2. Counter gear 3. 3rd gear bushing
4. 3rd needle bearing 5. 3rd counter gear 6. 3rd inner baulk ring
7. 3rd synchronizer cone 8. 3rd outer baulk ring 9. 3rd-4th spread spring
10. 3rd-4th shifting insert 11. 3rd-4th synchronizer hub 12. 3rd-4th coupling sleeve
13. 4th outer baulk ring 14. 4th synchronizer cone 15. 4th inner baulk ring
16. 4th gear bushing 17. 4th needle bearing 18. 4th counter gear
19. 4th counter gear thrust washer 20. Counter rear bearing inner race 21. Counter rear bearing
22. Counter rear bearing spacer 23. Reverse counter gear 24. Snap ring
25. Counter end bearing 26. Reverse idler shaft 27. Reverse idler needle bearing
28. Reverse idler gear 29. Reverse idler thrust washer
PCIB1617E
Page 2340 of 3171
TRANSMISSION ASSEMBLY
MT-23
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Shift Control Components
1. Check ball plug 2. Check ball spring 3. Check ball
4. Interlock pin 5. Interlock plunger 6. Retaining pin
7. 3rd-4th fork rod bracket 8. 3rd-4th fork rod 9. 1st-2nd fork rod
10. 1st-2nd shift fork 11. 3rd-4th fork rod (reversal side) 12. 3rd-4th shift fork
13. 5th-6th shift fork 14. 5th-6th fork rod (reversal side) 15. 5th-6th fork rod
16. 5th-6th fork rod bracket 17. 3rd-4th control lever 18. Shifter cap
19. 5th-6th control lever 20. Adapter plate
PCIB1597E
Page 2341 of 3171
MT-24
TRANSMISSION ASSEMBLY
1. Return spring plunger 2. Return spring 3. Return spring plug
4. Striking arm 5. Retaining pin 6. Stopper ring
7. Striking rod assembly 8. Adapter plate 9. Reverse fork rod
10. Reverse shift fork 11. Rear extension 12. OD gear case
: 2WD models
: 4WD models
Refer toGI-10, "
Components"and the followings for the symbols in the figure.
: Apply Genuine Liquid Gasket, Three Bond TB1215 or the equivalent.
: Apply gear oil.
PCIB1657E
Page 2342 of 3171
TRANSMISSION ASSEMBLY
MT-25
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DISASSEMBLY
Case Components
1. Remove drain plug and gasket from transmission case.
2. Remove clips from park/neutral position (PNP) switch and back-
up lamp switch.
3. Remove park/neutral position (PNP) switch, back-up lamp
switch and plungers from rear extension (or OD gear case).
4. Remove control housing mounting bolts, and then remove con-
trol housing and gasket from rear extension (or OD gear case).
5. Remove return spring plug, return spring and return spring
plunger from rear extension (or OD gear case).
PCIB1214E
PCIB1215E
PCIB1642E
PCIB1643E
Page 2343 of 3171
MT-26
TRANSMISSION ASSEMBLY
6. Remove rear oil seal from OD gear case using the puller (for
4WD models).
CAUTION:
Be careful not to damage OD gear case.
7. Remove retaining pin using a pin punch, and then remove strik-
ing arm from striking rod assembly.
8. Remove rear extension (or OD gear case) mounting bolts, and
then remove rear extension (or OD gear case) from adapter
plate using a soft hammer.
9. Remove rear extension oil gutter mounting bolt, and then
remove rear extension oil gutter and cap from rear extension (for
2WD models).
10. Remove dust seal and rear oil seal from rear extension using a
flat-bladed screwdriver (for 2WD models).
CAUTION:
Be careful not to damage rear extension.
PCIB1407E
PCIB1219E
PCIB1220E
PCIB1221E
PCIB1222E
Page 2344 of 3171
TRANSMISSION ASSEMBLY
MT-27
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11. Remove counter end bearing from rear extension (or OD gear
case) using a puller.
CAUTION:
Be careful not to damage rear extension (or OD gear case).
12. Remove withdrawal lever ball pin and washer from front cover.
13. Remove front cover mounting bolts, and then remove front cover
and front cover gasket from transmission case.
14. Remove front cover oil seal from front cover using a flat-bladed
screwdriver.
CAUTION:
Be careful not to damage front cover.
15. Remove baffle plate mounting nut from transmission case.
PCIB1223E
PCIB1401E
PCIB1225E
SCIA1399E
SCIA1443E