Manual Transmission Assy (R151F, R151) : Overhaul

41–7
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)
MANUAL TRANSMISSION ASSY (R151F, R151)

410JA–01
OVERHAUL
HINT:
COMPONENTS: See page 41–1.
1. REMOVE FILLER PLUG

(a) Remove the filler plug and gasket from the transmission
case.
D29023
2. REMOVE DRAIN PLUG

(a) Remove the drain plug and gasket from the transmission
case.
D29024
3. REMOVE CLUTCH RELEASE FORK SUB–ASSY

(a) Remove the release fork and release bearing from the
clutch housing.
D29025
4. REMOVE CLUTCH RELEASE BEARING ASSY

(a) Remove the clip, and then remove the release bearing
from the release fork.
D29026
R151, R151F M/T (Thailand) (DR176E)

41–8
5. REMOVE RELEASE FORK SUPPORT

(a) Remove the release fork support form the clutch housing.
D25933
6. REMOVE CLUTCH RELEASE FORK BOOT

(a) Remove the release fork boot from the clutch housing.
D29027
7. REMOVE CLUTCH HOUSING

(a) Remove the 9 bolts.
D29028
(b) Using a plastic–faced hammer, remove the clutch hous-

ing from the transmission case.
D29029
8. REMOVE BACK–UP LAMP SWITCH ASSY

(a) Using SST, remove the back–up lamp switch and gasket
from the transmission case.
SST 09817–16011
SST
D29030

41–9
R151F
9. REMOVE RESTRICT PIN
(a) Remove the 2 restrict pins from the transfer adapter
(R151F) or extension housing (R151).
R151
D29031
B85188
D33416
10. REMOVE CONTROL SHIFT LEVER RETAINER

R151F
(a) R151F:
Remove the 4 bolts.
(b) R151:
Remove the 6 bolts.
(c) Remove the control shift lever retainer.
(d) R151F:
Remove the oil deflector.
(e) R151:
Remove the control shift lever retainer gasket.
R151
D29032
B85189
D33417
11. R151F:
REMOVE TRANSFER CONTROL SHIFT LEVER
RETAINER
(b) Remove the shift lever retainer from the transfer adapter.
D29034

41–10
(c) Remove the select return spring from the shift lever re-
Transfer Select
tainer.
Return Spring
12. R151:
REMOVE SPEEDOMETER DRIVEN GEAR
(a) Remove the bolt and driven gear.
Transfer Control
Shift Lever
Retainer
D29035
13. R151F:
REMOVE SHIFT & SELECT LEVER SHAFT
(a) Using a 5mm pin punch and a hammer, tap out the slotted
spring pin from the shift lever housing.
D29038
(b) Remove the shift & select lever shaft and shift lever hous-
ing from the transfer adapter.
D29039
14. R151F:
REMOVE TRANSFER ADAPTER
D29033

41–11
(b) Using a brass bar and a hammer, tap out the transfer
adapter from the transmission case.
D29036
15. R151:
REMOVE EXTENSION HOUSING
(a) Remove the bolt from the shift lever housing.
G34547
(b) Remove the 10 bolts.
B85186
(c) Using a plastic–faced hammer, tap the extension housing

and remove the shift lever housing and shift & select lever
from the transmission case.
G34242

41–12
16. REMOVE OIL RECEIVER PIPE

(a) Remove the receiver pipe.
17. R151:
REMOVE OIL RECEIVER
(a) Remove the bolt and oil receiver.
D29037
18. REMOVE REVERSE RESTRICT PIN

(a) Using a T40 torx socket wrench, remove the plug.
D29040
(b) Using a 5 mm pin punch and a hammer, tap out the restrict
slotted pin.
D33421
(c) Remove the restrict pin.
D29042
19. R151F:
REMOVE TRANSFER ADAPTER OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from
the transfer adapter.
20. R151:
REMOVE EXTENSION HOUSING OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from
the extension housing.
D29043

41–13
21. REMOVE FRONT BEARING RETAINER

D25950
(b) Using a brass bar and a hammer, tap out the retainer from
the transmission case.
D25951
22. REMOVE TRANSMISSION FRONT BEARING

RETAINER OIL SEAL
SST (a) Fix the retainer in a vise.
(b) Using SST, tap out the oil seal.
SST 09308–00010
D25952
23. REMOVE FRONT BEARING SHAFT SNAP RING

(a) Using a snap ring expander, remove the snap ring from
D25953
24. REMOVE COUNTER GEAR FRONT BEARING SNAP

RING NO. 1
D25954

41–14
25. REMOVE MANUAL TRANSMISSION CASE

(a) Using a brass bar and a hammer, tap out the transmission
case from the intermediate plate.
D29044
26. REMOVE TRANSMISSION MAGNET

(a) Remove the magnet from the intermediate plate.
D25957
27. FIX INTERMEDIATE PLATE

(a) Fix the intermediate plate in a vise between the aluminum
plates.
D29045
28. REMOVE SHIFT DETENT BALL SPRING SEAT NO. 1

(a) Using a T40 torx socket wrench, remove the spring seat
from the intermediate plate.
D29046
(b) Using a magnetic finger, remove the compression spring

and detent ball from the intermediate plate.
D25960

41–15
(c) Using a T40 torx socket wrench, remove the 2 spring

seat from the intermediate plate.
D33569
(d) Using a magnetic finger, remove the 2 compression

springs and 2 detent balls from the intermediate plate.
D33570
29. REMOVE SHIFT FORK SHAFT NO. 2

(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft No. 2.
NOTICE:
Use a cloth to prevent the snap ring from flying off.
D29048
(b) Remove the bolt from the shift fork No. 2.
D29049
(c) Remove the shift fork shaft No. 2 from the intermediate
plate.
D29050

41–16
(d) Remove the shift fork No. 2 from the transmission hub
sleeve No. 2.
D29051
(e) Using a magnetic finger, remove the shift interlock No. 1

roller and shift interlock pin from the intermediate plate.
D25967

NOTICE:
D29052
(b) Remove the shift fork set bolt from the shift fork No. 1.
D29053
(c) Remove the shift fork shaft No. 1 from the intermediate
plate.
D29054

41–17
(d) Remove the shift fork No. 1 from the reverse gear.
D29055
(e) Using a magnetic finger, remove the shift interlock No. 1

roller from the intermediate plate.
D25975

(a) Using a 5 mm pin punch and a hammer, tap out the shift
fork set slotted spring pin from the shift fork No. 3.
D29056
(b) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft.
NOTICE:
D29057
(c) Remove the shift fork No. 3 and shift fork shaft No. 3 from
the intermediate plate.
D29058

41–18
(d) Using a magnetic finger, remove the shift interlock No. 1

roller from the intermediate plate.
D25975
(e) Using a magnetic finger, remove the reverse shift fork ball
from the reverse shift fork.
D25979

NOTICE:
D25980
(b) Remove the shift fork shaft No. 4 from the intermediate
plate.
NOTICE:
Cover the hole with a cloth to prevent the reverse shift fork
ball from popping out.
C89440
(c) Using a magnetic finger, remove the reverse shift fork re-
turn compression spring from the reverse shift fork.
D25982

41–19
33. REMOVE REVERSE SHIFT FORK

(a) Remove the reverse shift fork (with the reverse shift arm)
from the intermediate plate.
D25983
(b) Using a screwdriver, pry out the E–ring and reverse shift
fork from the reverse shift arm.
D25984
34. REMOVE REVERSE SHIFT ARM BRACKET

(a) Remove the 2 bolts and reverse shift arm bracket from the
intermediate plate.
D25985
35. R151:
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the drive gear.
(c) Using a magnetic finger, remove the steel ball.
(d) Using snap ring pliers, remove the snap ring.
G34243
36. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP

RING
(a) Using 2 screwdrivers and a hammer, tap out the shaft
snap ring from the output shaft.
D29059

41–20
37. REMOVE OUTPUT SHAFT REAR BEARING

R151F
(a) Using SST, remove the rear bearing and output shaft
spacer from the output shaft.
SST 09950–40011 (09951–04010, 09952–04010,
09953–04020, 09954–04010, 09955–04051,
SST 09957–04010, 09958–04011)
R151
SST
D25987
B85191
D33422
38. INSPECT COUNTER 5TH GEAR CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
If the clearance is not as specified, replace the counter 5th gear.
D25991
39. INSPECT COUNTER 5TH GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 to 0.068 mm (0.0059 to 0.0027 in.)
If the clearance is not as specified, replace the counter 5th gear
bearing with a new one.
D25992
40. REMOVE COUNTER GEAR REAR SHAFT SNAP RING

from the counter gear.
D25993

41–21
41. REMOVE GEAR SPLINE PIECE NO. 5

(a) Using SST, remove the gear spline piece from the counter
SST gear.
SST 09950–50013 (09951–05010, 09952–05010,
09953–05020, 09954–05021, 09957–04010)
D25994
42. REMOVE SYNCHRONIZER RING NO. 3

(a) Remove the synchronizer ring from the counter gear.
D29060
43. REMOVE COUNTER 5TH GEAR

(a) Remove the counter 5th gear and transmission hub
sleeve No. 3 assembly from the counter gear.
D29061
44. REMOVE COUNTER 5TH GEAR BEARING

(a) Remove the bearing from the counter 5th gear.
C89839
45. REMOVE TRANSMISSION HUB SLEEVE NO. 3

(a) Using a snap ring expander, remove the snap ring.
D29062

41–22
(b) Remove the transmission hub sleeve No. 3, 2 synchro-

mesh shifting keys No. 3 and 2 synchromesh shifting key
springs No. 3 from the counter 5th gear.
D29063
46. REMOVE 5TH GEAR THRUST WASHER

(a) Remove the thrust washer from the counter gear.
D25999
47. REMOVE 5TH GEAR THRUST WASHER PIN

(a) Remove the thrust washer pin from the counter gear.
D26000
48. REMOVE REAR BEARING RETAINER

(a) Remove the 4 bolts and bearing retainer from the inter-
mediate plate.
D26001
49. REMOVE REVERSE IDLER GEAR

(a) Pull out the reverse idler gear shaft to the rear side and
remove the reverse idler gear from the intermediate plate.
D26002

41–23
50. REMOVE COUNTER SHAFT CENTER BEARING

(a) Using a snap ring expander, remove the snap ring.
D29260
(b) Using SST, remove the center bearing from the intermedi-
ate plate.
SST SST 09950–40011 (09951–04010, 09952–04010,
09953–04020, 09954–04010, 09955–04011,
09957–04010, 09958–04011)
HINT:
Remove the bearing while tapping the tip of the counter gear so
that the counter gear does not hit the side wall of the output
D26004 shaft gear by being pushed forward.
51. REMOVE COUNTER GEAR

(a) Remove the counter gear from the intermediate plate.
D26005
52. REMOVE INPUT SHAFT ASSY

(a) Remove the input shaft and synchronizer ring No. 2 from
the output shaft.
NOTICE:
Do not drop the input shaft bearing and the synchronizer
ring No. 2.
D26006
53. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP

RING
the output shaft.
D29064

41–24
54. REMOVE OUTPUT SHAFT ASSY

(a) Using a plastic–faced hammer, remove the output shaft
by tapping the intermediate plate.
D29065
55. INSPECT SYNCHRONIZER RING NO. 3

(a) Apply gear oil to the cone part of the gear spline piece No.
5, and check that it does not turn in both directions while
pushing the synchronizer ring No. 3 to the gear spline
piece No. 5.
If it can turn, replace the synchronizer ring No. 3.
D29110
(b) Push the synchronizer ring outer No. 3 to the cone part of
the gear spline piece No. 5. Measure the clearance be-
tween the synchronizer ring outer No. 3 and gear spline
piece No. 5.
Standard clearance:
0.68 to 1.32 mm (0.0268 to 0.0519 in.)
If the clearance is not as specified, replace synchronizer ring
outer No. 3 with a new one.
D29111
56. INSPECT TRANSMISSION HUB SLEEVE NO. 3

(a) Check the sliding condition between the counter shaft 5th
gear and transmission hub sleeve No. 3.
(b) Check the tip of the spline gear of the transmission hub
sleeve No. 3 for wear.
If there are any defects, replace the transmission hub sleeve
No. 3.
D26011

41–25
(c) Using a vernier caliper, measure the transmission hub

sleeve No. 3 groove and the thickness of the claw part of
the shift fork No. 3 to calculate the clearance.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
If the clearance is not as specified, replace the transmission
hub sleeve No. 3 and shift fork No. 3 with new ones.
D26012
57. INSPECT COUNTER 5TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the counter 5th gear.
Standard inside diameter:
38.015 to 38.040 mm (1.4967 to 1.4976 in.)
Maximum inside diameter: 38.040 mm (1.4976 in.)
If the inside diameter is not as specified, replace the counter
shaft 5th gear with a new one.
D26013
58. INSPECT REVERSE IDLER GEAR SUB–ASSY

(a) Using a caliper gauge, measure the inside diameter of the
reverse idler gear.
Standard inside diameter:
24.040 to 24.061 mm (0.9465 to 0.9473 in.)
Maximum inside diameter: 24.061 mm (0.9473 in.)
If the inside diameter is not as specified, replace the reverse
idler gear with a new one.
(b) Using a micrometer, measure the diameter of the sliding
part of the reverse idler gear on the reverse idler gear
shaft.
Standard diameter:
23.979 to 24.000 mm (0.9441 to 0.9449 in.)
Minimum diameter: 23.979 mm (0.9441 in.)
If the diameter is not as specified, replace the reverse idler gear
shaft.
D26014

41–26
(c) Using a feeler gauge, measure the thrust clearance of the

shoe part between the reverse idler gear and reverse shift
arm.
Standard clearance:
0.05 to 0.35 mm (0.0020 to 0.0138 in.)
If the clearance is not as specified, replace the reverse idler
gear and reverse shift arm.
D26015
59. INSPECT REVERSE IDLER GEAR RADIAL

CLEARANCE
(a) Install the reverse idler gear on the reverse idler gear
shaft, and clamp it to a vise.
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.040 to 0.082 mm (0.0016 to 0.0032 in.)
If the clearance is not as specified, replace the reverse idler
D26016 gear.
60. INSTALL OUTPUT SHAFT ASSY

(a) Apply gear oil to the sliding part of the output shaft.
(b) Using a plastic–faced hammer, install the output shaft by
tapping the intermediate plate.
D29112
61. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP

RING
(a) Using a snap ring expander, install the shaft snap ring to
the output shaft.
D29064
62. INSTALL INPUT SHAFT ASSY

(a) Apply gear oil to the input shaft and synchronizer ring No.
2, and install them to the output shaft.
NOTICE:
S Install the synchronizer ring No. 2 so that its groove
fits into the synchromesh shifting key No. 2.
S Check that the input shaft rotates slightly.
D26006

41–27
63. INSTALL COUNTER GEAR

(a) Temporarily install the counter gear to the intermediate
plate.
D26005
64. INSTALL COUNTER SHAFT CENTER BEARING

(a) Using SST and a hammer, tap in a new center bearing to
SST 09316–60011 (09316–00011)
SST
HINT:
Install the bearing while tapping the tip of the counter gear with
a plastic hammer so that the counter gear will not hit the side
wall of the output shaft gear by being pushed forward.
D29113
65. INSTALL REVERSE IDLER GEAR

(a) Apply gear oil to each sliding part of the reverse idler gear
and the reverse idler gear shaft, and install the reverse
idler gear and the reverse idler shaft to the intermediate
plate.
NOTICE:
Face the groove side of the reverse idler shaft to the rear
side, and install it from the rear side.
D26002
66. INSTALL REAR BEARING RETAINER

(a) Install the bearing retainer inserting to the groove of the
reverse idler gear shaft with the 4 bolts.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)
D26001
67. INSTALL 5TH GEAR THRUST WASHER PIN

(a) Apply MP grease to the washer pin, and install it to the
counter gear.
D26000

41–28
68. INSTALL 5TH GEAR THRUST WASHER

(a) Apply gear oil to the thrust washer, and install it to the
counter gear.
NOTICE:
Install the thrust washer so that its chamfer side faces to
the front side.
D25999
69. INSTALL TRANSMISSION HUB SLEEVE NO. 3

(a) Apply gear oil to the sliding part of transmission hub
sleeve No. 3, and install it to the counter 5th gear.
NOTICE:
Be sure of the direction of the transmission hub sleeve No.
3 and the counter 5th gear.
(b) Install the 2 synchromesh shifting keys No. 3 and 2 syn-
chromesh shifting key springs to the counter 5th gear.
D29063
(c) Using snap ring expander, install the snap ring to the
counter 5th gear.
D29062
70. INSTALL COUNTER 5TH GEAR BEARING

(a) Apply gear oil to the bearing and install it to the counter
5th gear.
D26020
71. INSTALL COUNTER 5TH GEAR

(a) Apply gear oil to the 5th gear and transmission hub sleeve
No. 3, and install it to the counter gear.
D25996

41–29
72. INSTALL SYNCHRONIZER RING NO. 3

(a) Apply gear oil to the synchronizer ring No. 3, and install
it to the counter gear.
NOTICE:
Install the synchronizer ring No. 3 so that its groove fits into
the synchromesh shifting key No. 3.
D29060
73. INSTALL GEAR SPLINE PIECE NO. 5

(a) Using SST and a press, press in the gear spline piece to
SST
the counter gear.
SST 09316–60011 (09316–00011)
NOTICE:
Check that the gear rotate freely.
D26022
74. INSTALL COUNTER GEAR REAR SHAFT SNAP RING

(a) Select the snap ring so that the thrust gap between the
gear spline piece No. 5 and snap ring to be within the
specification.
Standard clearance: 0.1 mm (0.0039 in.) or less
Mark Thickness
A 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
B 2.85 to 2.90 mm (0.1122 to 0.1141 in.)
C 2.90 to 2.95 mm (0.1141 to 0.1160 in.)
D 2.95 to 3.00 mm (0.1160 to 0.1181 in.)
E 3.00 to 3.05 mm (0.1181 to 0.1200 in.)
F 3.05 to 3.10 mm (0.1200 to 0.1220 in.)
G 3.10 to 3.15 mm (0.1220 to 0.1240 in.)
(b) Using a brass bar and a hammer, tap in the snap ring.
D26023

41–30
75. INSPECT COUNTER 5TH GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
If the clearance is not as specified, replace the counter shaft 5th
gear and synchronizer ring No. 3.
D25991
76. INSPECT COUNTER 5TH GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, check the gear radial clearance.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
If the clearance is not as specified, replace the counter 5th gear
bearing.
D25992
77. INSTALL OUTPUT SHAFT REAR BEARING

(a) Using SST and a press, press in the spacer and a new
SST rear bearing to the output shaft.
SST 09309–35010
D26024
78. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

(a) Select a shaft snap ring so that the thrust gap between the output shaft bearing shaft and snap ring
to be within the specification.
Standard clearance: 0.1 mm (0.0039 in.) or less
Mark Thickness Mark Thickness
A 2.65 to 2.70 mm (0.1043 to 0.1063 in.) K 3.10 to 3.15 mm (0.1220 to 0.1240 in.)
B 2.70 to 2.75 mm (0.1063 to 0.1083 in.) L 3.15 to 3.20 mm (0.1240 to 0.1260 in.)
C 2.75 to 2.80 mm (0.1083 to 0.1102 in.) M 3.20 to 3.25 mm (0.1260 to 0.1280 in.)
D 2.80 to 2.85 mm (0.1102 to 0.1122 in.) N 3.25 to 3.30 mm (0.1280 to 0.1299 in.)
E 2.85 to 2.90 mm (0.1122 to 0.1141 in.) P 3.30 to 3.35 mm (0.1299 to 0.1319 in.)
F 2.90 to 2.95 mm (0.1141 to 0.1160 in.) Q 3.35 to 3.40 mm (0.1319 to 0.1339 in.)
G 2.95 to 3.00 mm (0.1160 to 0.1181 in.) R 3.40 to 3.45 mm (0.1339 to 0.1358 in.)
H 3.00 to 3.05 mm (0.1181 to 0.1200 in.) S 3.45 to 3.50 mm (0.1358 to 0.1378 in.)
J 3.05 to 3.10 mm (0.1200 to 0.1220 in.)

41–31
(b) Using a brass bar and a hammer, tap in the snap ring.
D25988
79. R151:
INSTALL SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, install the snap ring.
(b) Install the ball and drive gear.
(c) Using snap ring pliers, install the snap ring.
G34243
80. INSTALL REVERSE SHIFT ARM BRACKET

(a) Install the arm bracket on the intermediate plate with the
2 bolts.
D25985
81. INSTALL REVERSE SHIFT FORK

(a) Install the shift arm to the shift fork. Using a screwdriver
and a hammer, tap in a new E–ring.
D26025
(b) Install the tip of the reverse shift arm to the reverse idler
gear. Align the cut end of the reverse shift arm with the re-
verse shift arm bracket pin, and install them.
D26026

41–32
82. INSTALL SHIFT FORK SHAFT NO. 4

(a) Install the compression spring and reverse shift fork ball
to the reverse shift fork.
D26027
(b) Apply gear oil to the sliding part of the shift fork shaft No.
4.
(c) Using a screwdriver, install the shift fork shaft No. 4 by
pushing the reverse shift fork ball lightly.
D25981
(d) Using a brass bar and a hammer, tap in the snap ring to
the shift fork shaft No. 4.
D26028

(a) Install the reverse shift fork ball to the reverse shift fork.
D25979
(b) Install the shift interlock No. 1 roller to the intermediate

plate.
D25975

41–33
(c) Install the shift fork No. 3 to the transmission hub sleeve
No. 3 and shift fork shaft No. 3 to the intermediate plate
from the front side.
D29058
(d) Using a brass bar and a hammer, tap in the snap ring to
the shift fork shaft.
D29114
(e) Using a 5 mm pin punch and a hammer, tap in the slotted

spring pin to the shift fork No. 3.
D29056

(a) Install the shift interlock No. 1 roller to the intermediate
plate.
D25975
(b) Install the shift fork No. 1 to the reverse gear.
D29055

41–34
(c) Install the shift fork shaft No. 1 to the intermediate plate
from the rear side.
D29054
(d) Install the shift fork set bolt to the shift fork No. 1.
D29053
(e) Using a brass bar and a hammer, tap in the shift fork shaft
snap ring to the shift fork shaft No. 1.
D29115

(a) Install the shift interlock pin and shift interlock No.1 roller
to the intermediate plate.
D25967
(b) Install the shift fork No. 2 to the transmission hub sleeve
No. 2.
D29051

41–35
(c) Apply gear oil to the shift fork shaft No. 2, and install it to
the intermediate plate from the rear side.
D29050
(d) Install the shift fork set bolt to the shift fork No. 2.
D29049
(e) Using a brass bar and a hammer, tap in the snap ring to
the shift fork shaft No. 2.
D29116
86. INSTALL SHIFT DETENT BALL SPRING SEAT NO. 1

(a) Install the 2 compression springs and 2 shift detent balls
D33570
(b) Using a T40 torx socket wrench, install the 3 spring seat
Torque: 18.5 N⋅m (190 kgf⋅cm, 14 ft⋅lbf)
D33569

41–36
(c) Install the detent ball and low side compression spring to
D25960
(d) Using a T40 torx socket wrench, install the spring seat
D29046
87. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet, and install it to the inter-
mediate plate.
D25957
88. INSTALL MANUAL TRANSMISSION CASE

(a) Apply seal packing to the manual transmission case as
shown in the illustration.
Seal packing:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent.
D25957
(b) Using a plastic–faced hammer, tap the transmission case

to attach it to the intermediate plate.
D29117

41–37
89. INSTALL COUNTER GEAR FRONT BEARING SNAP

RING NO. 1
(a) Using a snap ring expander, install the snap ring to the
transmission case.
D25954
90. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using a snap ring expander, install the snap ring to the
transmission case.
D25953
91. INSTALL TRANSMISSION FRONT BEARING

SST RETAINER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to the front
bearing retainer.
SST 09950–60010 (09951–00300, 09951–00520,
09952–06010), 09950–70010 (09951–07100)
Standard clearance:
11.2 to 12.2 mm (0.4409 to 0.4803 in.)
D26035 (b) Lightly apply MP grease to the tip of the oil seal.
92. INSTALL FRONT BEARING RETAINER

(a) Apply seal packing to the bearing retainer as shown in the
illustration.
Seal Seal packing:
Packing Part No. 08826–00090, THREE BOND 1281 or equiva-
lent.
D26036
(b) Install the bearing retainer front to the transmission case

with the 8 bolts.
(c) Check that the input shaft and output shaft rotate smooth-
ly.
D25950

41–38
93. R151F:
SST
INSTALL TRANSFER ADAPTER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to the
transfer adapter.
SST 09710–30050, 09950–70010 (09951–07100)
Oil seal depth: 45.4 to 46.4 mm (1.7874 to 1.8268 in.)
(b) Lightly apply MP grease to the tip of the oil seal.
D29118
94. R151:
INSTALL EXTENSION HOUSING OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to the ex-
tension housing.
SST 09710–30050, 09950–70010 (09951–07100)
Oil seal depth: 0 " 0.5 mm (0 " 0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
D33420 (b) Lightly apply MP grease to the tip of the oil seal.
95. INSTALL REVERSE RESTRICT PIN

(a) Install the restrict pin to the transfer adapter (R151F) or
extension housing (R151).
D29042
(b) Using a 5 mm pin punch and a hammer, tap in the slotted

pin to the transfer adapter (R151F) or extension housing
(R151).
D33421
(c) Using a T40 torx socket wrench, install the reverse re-
strict pin plug to the transfer adapter.
96. R151:
INSTALL OIL RECEIVER
(a) Install the oil receiver with the bolt.
D29040

41–39
97. INSTALL OIL RECEIVER PIPE

(a) Install the oil receiver pipe to the transfer adapter (R151F)
or extension housing (R151).
D29037
98. R151F:
INSTALL TRANSFER ADAPTER
(a) Apply seal packing to the transfer adapter as shown in the
Seal illustration.
Packing Seal packing:
lent.
D29067
(b) Using a plastic–faced hammer, tap the transfer adapter to

attach it to the transmission case.
D29119
(c) Install the transfer adapter to the transmission case with

the 10 bolts.
D29033

41–40
99. R151:
INSTALL EXTENSION HOUSING
(a) Apply seal packing to the extension housing as shown in
the illustration.
Seal
Seal packing:
Packing
lent.
(b) Insert the shift & select lever to the extension housing.
D29067
(c) Connect the shift & select lever to the fork shaft and put
in the shift lever housing.
(d) Align the shift & select lever to the extension housing
installation hole and push in the extension housing.
G34242
(e) Install the extension housing to the case with the 10 bolts.
B85186
(f) Install the shift lever housing bolt to the shift lever hous-
ing.
G34547

41–41
100. R151F:
INSTALL SHIFT & SELECT LEVER SHAFT
(a) Install the shift & select lever shaft and shift lever housing
to the transfer adapter.
D29039
(b) Using a 5 mm pin punch and a hammer, tap in the slotted

spring pin to the transfer adapter.
101. R151:
INSTALL SPEEDOMETER DRIVEN GEAR
(a) Install the a new O–ring to the driven gear.
(b) Install the driven gear with the bolt.
D29038
102. R151F:
Transfer Select
INSTALL TRANSFER CONTROL SHIFT LEVER
Return Spring
RETAINER
(a) Install the select return spring on the shift lever retainer.
Transfer Control
Shift Lever
Retainer
D29035
(b) Install the shift lever retainer to the transfer adapter with
the 4 bolts.
D29034

41–42
103. INSTALL CONTROL SHIFT LEVER RETAINER

R151F
(a) Install the control shift lever retainer and oil deflector
(R151F) or control shift lever retainer gasket (R151).
(b) R151F:
Install the 4 bolts.
(c) R151:
Install the 6 bolts.
R151
D29032
B85189
D33417
R151F White
104. INSTALL RESTRICT PIN
(a) Install the 2 restrict pins.
Front
Side
Green
R151 White
Front
Side
D29031
B85188
Green
D33416
105. INSTALL BACK–UP LAMP SWITCH ASSY

(a) Using SST, install a new gasket and back–up lamp switch
and to the transmission case.
SST 09817–16011
SST
D29030

41–43
106. INSTALL CLUTCH HOUSING

(a) Install the clutch housing to the transmission case with
the 9 bolts.
D29028
107. INSTALL CLUTCH RELEASE FORK BOOT

(a) Install the fork boot to the clutch housing.
D29027
108. INSTALL RELEASE FORK SUPPORT

(a) Install the release fork support to the clutch housing.
D25933
109. INSTALL CLUTCH RELEASE BEARING ASSY

(a) Apply clutch release hub grease to the clutch release
bearing, and install it to the clutch release fork.
D29899

41–44
110. INSTALL CLUTCH RELEASE FORK SUB–ASSY

(a) Install the clutch release fork.
(b) Apply the clutch spline grease to the spline of the input
shaft.
D29025
111. INSTALL DRAIN PLUG

(a) Install a new gasket and drain plug to the transmission
case.
D29024
112. INSTALL FILLER PLUG

(a) Install a new gasket and filler plug to the transmission
case.
D29023

Manual Transmission Assy (R151F, R151) : Overhaul

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Manual Transmission Assy (R151F, R151) : Overhaul

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41–7

MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

MANUAL TRANSMISSION ASSY (R151F, R151)

1. REMOVE FILLER PLUG

2. REMOVE DRAIN PLUG

3. REMOVE CLUTCH RELEASE FORK SUB–ASSY

4. REMOVE CLUTCH RELEASE BEARING ASSY

R151, R151F M/T (Thailand) (DR176E)

5. REMOVE RELEASE FORK SUPPORT

6. REMOVE CLUTCH RELEASE FORK BOOT

7. REMOVE CLUTCH HOUSING

(b) Using a plastic–faced hammer, remove the clutch hous-

8. REMOVE BACK–UP LAMP SWITCH ASSY

R151, R151F M/T (Thailand) (DR176E)

10. REMOVE CONTROL SHIFT LEVER RETAINER

R151, R151F M/T (Thailand) (DR176E)

R151, R151F M/T (Thailand) (DR176E)

(b) Remove the 10 bolts.

(c) Using a plastic–faced hammer, tap the extension housing

R151, R151F M/T (Thailand) (DR176E)

16. REMOVE OIL RECEIVER PIPE

18. REMOVE REVERSE RESTRICT PIN

(c) Remove the restrict pin.

R151, R151F M/T (Thailand) (DR176E)

21. REMOVE FRONT BEARING RETAINER

22. REMOVE TRANSMISSION FRONT BEARING

23. REMOVE FRONT BEARING SHAFT SNAP RING

24. REMOVE COUNTER GEAR FRONT BEARING SNAP

R151, R151F M/T (Thailand) (DR176E)

25. REMOVE MANUAL TRANSMISSION CASE

26. REMOVE TRANSMISSION MAGNET

27. FIX INTERMEDIATE PLATE

28. REMOVE SHIFT DETENT BALL SPRING SEAT NO. 1

(b) Using a magnetic finger, remove the compression spring

R151, R151F M/T (Thailand) (DR176E)

(c) Using a T40 torx socket wrench, remove the 2 spring

(d) Using a magnetic finger, remove the 2 compression

29. REMOVE SHIFT FORK SHAFT NO. 2

(b) Remove the bolt from the shift fork No. 2.

R151, R151F M/T (Thailand) (DR176E)

(e) Using a magnetic finger, remove the shift interlock No. 1

30. REMOVE SHIFT FORK SHAFT NO. 1

R151, R151F M/T (Thailand) (DR176E)

(e) Using a magnetic finger, remove the shift interlock No. 1

31. REMOVE SHIFT FORK SHAFT NO. 3

R151, R151F M/T (Thailand) (DR176E)

(d) Using a magnetic finger, remove the shift interlock No. 1

32. REMOVE SHIFT FORK SHAFT NO. 4

R151, R151F M/T (Thailand) (DR176E)

33. REMOVE REVERSE SHIFT FORK

34. REMOVE REVERSE SHIFT ARM BRACKET

36. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP

R151, R151F M/T (Thailand) (DR176E)

37. REMOVE OUTPUT SHAFT REAR BEARING

38. INSPECT COUNTER 5TH GEAR CLEARANCE

39. INSPECT COUNTER 5TH GEAR RADIAL

40. REMOVE COUNTER GEAR REAR SHAFT SNAP RING

R151, R151F M/T (Thailand) (DR176E)

41. REMOVE GEAR SPLINE PIECE NO. 5

42. REMOVE SYNCHRONIZER RING NO. 3

43. REMOVE COUNTER 5TH GEAR

44. REMOVE COUNTER 5TH GEAR BEARING

45. REMOVE TRANSMISSION HUB SLEEVE NO. 3