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Transmission - 4x4, Vehicles With: 5-Speed Manual Transmission (S15M)-5-Speed Manual Transmission (S15MX) > < Transmission - Vehicles With: 5-Speed Manual Transmission (R15M)

Ranger 2006.5 (05.2006-)

Manual Transmission/Transaxle - Transmission—4x2, Vehicles With: 5-Speed Manual Transmission (S15M)/5-Speed Manual Transmission (S15MX) Ranger 2006.5 (05/2006-)
Disassembly

Special Tool(s)

Piston Pin Installer

49 0636 040

Bearing Puller Set

49 0839 425C

Attachment A

49 B032 308

Wrench

49 F017 1A0

Handle

49 G033 102

Hook

49 H017 101

Socket

49 UN01 011
CAUTION:
CAUTION:Remove the oil seal (extension housing and control rod) only if there is a malfunction.

1. Disassemble the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Release fork
2
-
Release collar
3
-
Dust boot
4
-
Top cover, shift component
See Disassembly Detail
5
-
Oil passage
6
-
Control lever
7
-
Dust boot
8
-
Gasket
9
-
Wave washer
10
-
Change bush
11
-
Shift lever
12
-
Change seat
13
-
Control case
14
-
Control rod end
15
-
Blind cover
16
-
Neutral switch
17
-
Vehicle speed sensor
18
-
Back-up light switch
19
-
Select spindle component
20
-
Spring cap
21
-
Select lock spindle spring
22
-
Select lock spindle
23
-
Oil seal (extension housing)
See Disassembly Detail
24
-
Extension housing
See Disassembly Detail
25
-
Funnel
26
-
Control rod
27
-
Oil passage
28
-
Oil seal (control rod)
See Disassembly Detail
29
-
Bush
See Disassembly Detail
30
-
Sealing cap
See Disassembly Detail
31
-
Retaining ring
32
-
Speed drive gear
33
-
Steel ball

 
Item
Part Number
Description
34
-
Locknut
See Disassembly Detail
35
-
Countershaft rear bearing
36
-
Thrust washer
37
-
Locknut
See Disassembly Detail
38
-
Mainshaft rear bearing
See Disassembly Detail
39
-
Reverse counter gear
40
-
Spacer
41
-
Retaining bolt
42
-
Reverse idler gear shaft component
See Disassembly Detail
43
-
Retaining ring
44
-
Thrust washer
45
-
Reverse idler gear
46
-
Needle bearing
47
-
Thrust washer
48
-
Reverse idler gear shaft
49
-
Friction damper
See Disassembly Detail
50
-
Reverse gear
51
-
Needle bearing
52
-
Thrust washer
53
-
Thrust washer
54
-
Synchronizer ring
55
-
Retaining ring
56
-
Washer
57
-
Counter lever
See Disassembly Detail
58
-
Retaining bolt
59
-
Counter lever shaft component
See Disassembly Detail
60
-
Retaining bolt
61
-
5th/reverse clutch hub and shift fork component
See Disassembly Detail
62
-
5th/reverse shift fork
63
-
5th/reverse shift rod
64
-
Detent ball
65
-
Detent spring
66
-
Clutch hub sleeve
67
-
Synchronizer key
68
-
Synchronizer key spring
69
-
5th/reverse clutch hub
70
-
Synchronizer ring
71
-
5th gear
72
-
Needle bearing
73
-
5th gear bearing inner race
74
-
Steel ball
75
-
5th counter gear

 
Item
Part Number
Description
76
-
Bearing cover
77
-
Front cover
See Disassembly Detail
78
-
Pivot pin
79
-
Bearing shim
80
-
Oil baffle
81
-
Bearing shim
82
-
Maindrive gear bearing race
83
-
Mainshaft bearing race
See Disassembly Detail
84
-
Countershaft front bearing
85
-
Countershaft rear bearing
86
-
Mainshaft component
See Disassembly Detail
87
-
Maindrive gear
88
-
Countershaft component
89
-
Front oil seal
90
-
Transmission case

Disassembly Details

Item 4 : Top cover, shift component
  1. Pry the seal open at the projection on the case using a flathead screwdriver or similar tool as shown in the figure, and then remove the top cover.

Item 23 : Oil seal (extension housing)
  1. Remove the oil seal using a flathead screwdriver as shown in the figure.

Item 24 : Extension housing
  1. NOTE:
    NOTE:Pry open the seal at the projection on the case using a flathead screwdriver or similar tool as shown in the figure, and then remove the extension housing.
    Remove the extension housing component.

Item 28 : Oil seal (control rod)
  1. Using a flathead screwdriver, remove the oil seal as shown in the figure.

Item 29 : Bush
  1. Remove the bush using the SST.

  1. Remove the bush using the suitable steel bar through the sealing cap hole as shown in the figure.
    1. Distance A: Approx. 200 mm {7.87 in}
    1. Distance B: Approx. 17.0—17.5 mm {0.670—0.688 in}

Item 30 : Sealing cap
  1. CAUTION:
    CAUTION:Remove the sealing cap only if there is malfunction.
    Remove the sealing cap using the SST.

Item 34 : Locknut
  1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves to lock the transmission into 4th and 2nd gears.

  1. Remove the countershaft rear bearing locknut by rotating it clockwise.

  1. Remove the mainshaft rear bearing locknut by rotating it counterclockwise using the SST.

Item 37 : Locknut
  1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves to lock the transmission into 4th and 2nd gears.

  1. Remove the countershaft rear bearing locknut by rotating it clockwise.

  1. Remove the mainshaft rear bearing locknut by rotating it counterclockwise using the SST.

Item 38 : Mainshaft rear bearing
  1. Using the SSTs remove the mainshaft rear bearing.

Item 42 : Reverse idler gear shaft component
  1. Remove the reverse idler gear shaft retaining bolt and then remove the reverse idler gear shaft component from the transmission case.

Item 49 : Friction damper
  1. Remove the friction damper using a flathead screwdriver.

Item 57 : Counter lever
  1. CAUTION:
    CAUTION:To prevent the shaft position from deviating when removing the counter lever, remove the countershaft lever component without loosening the locknut unless it is necessary.

Item 59 : Counter lever shaft component
  1. CAUTION:
    CAUTION:To prevent the shaft position from deviating when removing the counter lever, remove the countershaft lever component without loosening the locknut unless it is necessary.

Item 61 : 5th/reverse clutch hub and shift fork component
  1. Remove the 5th/reverse shift rod retaining bolt.

  1. Remove the 5th/reverse shift fork component and 5th/reverse clutch hub component at the same time.

Item 77 : Front cover
  1. CAUTION:
    CAUTION:Insert the front cover tightening bolts into the bolt holes for the front cover disassembly, tighten the two bolts uniformly and, then remove the front cover.
    Remove the front cover.

Item 83 : Mainshaft bearing race
  1. Grasping the mainshaft and countershaft, move them forward and back to remove the bearing races.

Item 86 : Mainshaft component
  1. Tilt the mainshaft component as shown in the figure and remove it from the transmission case.

  1. Remove the maindrive gear.

  1. Tilt the countershaft component as shown in the figure and remove it from the transmission case.

Transmission - 4x4, Vehicles With: 5-Speed Manual Transmission (S15M)-5-Speed Manual Transmission (S15MX) > < Transmission - Vehicles With: 5-Speed Manual Transmission (R15M)