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Disassembly and Assembly of Subassemblies > < Transmission - 4x2, Vehicles With: 5-Speed Manual Transmission (S15M)-5-Speed Manual Transmission (S15MX)

Ranger 2006.5 (05.2006-)

Manual Transmission/Transaxle - Transmission—4x4, 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

Wrench

49 F017 1A0

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 rod end
7
-
Dust boot
8
-
Gasket
9
-
Wave washer
10
-
Change bush
11
-
Shift lever
12
-
Transfer shift lever
13
-
Change seat
14
-
Transfer neutral switch
15
-
Switch pin
16
-
Spring
17
-
Steel ball
18
-
4x4 indicator switch
19
-
Vehicle speed sensor
20
-
Neutral switch
21
-
Back-up light switch
22
-
Breather dust boot
23
-
Breather
24
-
Transfer
25
-
Blind cover
26
-
Extension housing
See Disassembly Detail
27
-
Funnel
28
-
Oil seal (extension housing)
See Disassembly Detail
29
-
Oil seal (control rod)
See Disassembly Detail
30
-
Bush
See Disassembly Detail

 
Item
Part Number
Description
31
-
Locknut
See Disassembly Detail
32
-
Countershaft rear bearing
33
-
Thrust washer
34
-
Locknut
See Disassembly Detail
35
-
Mainshaft rear bearing
See Disassembly Detail
36
-
Reverse counter gear
37
-
Spacer
38
-
Retaining bolt
39
-
Reverse idler gear shaft component
40
-
Retaining ring
41
-
Thrust washer
42
-
Reverse idler gear
43
-
Needle bearing
44
-
Thrust washer
45
-
Reverse idler gear shaft
46
-
Friction damper
See Disassembly Detail
47
-
Reverse gear
48
-
Needle bearing
49
-
Thrust washer
50
-
Thrust washer
51
-
Synchronizer ring
52
-
Retaining ring
53
-
Washer
54
-
Counter lever
See Disassembly Detail
55
-
Retaining bolt
56
-
Counter lever shaft component
See Disassembly Detail
57
-
Retaining bolt
58
-
5th/reverse clutch hub and shift fork component
See Disassembly Detail
59
-
5th/reverse shift fork
60
-
5th/reverse shift rod
61
-
Detent ball
62
-
Detent spring
63
-
Clutch hub sleeve
64
-
Synchronizer key
65
-
Synchronizer key spring
66
-
5th/reverse clutch hub
67
-
Synchronizer ring
68
-
5th gear
69
-
Needle bearing
70
-
5th gear bearing inner race
71
-
Steel ball
72
-
5th counter gear

 
Item
Part Number
Description
73
-
Bearing cover
74
-
Front cover
See Disassembly Detail
75
-
Pivot pin
76
-
Bearing shim
77
-
Oil baffle
78
-
Bearing shim
79
-
Maindrive gear bearing race
See Disassembly Detail
80
-
Mainshaft bearing race
81
-
Countershaft front bearing
82
-
Countershaft rear bearing
83
-
Mainshaft component
See Disassembly Detail
84
-
Maindrive gear
85
-
Countershaft component
86
-
Front oil seal
-
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 26 : 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 (extension housing)
  1. Remove the oil seal using a flathead screwdriver as shown in the figure.

Item 29 : Oil seal (control rod)
  1. Using a flathead screwdriver, remove the oil seal as shown in the figure.

Item 30 : Bush
  1. NOTE:
    NOTE:Front side
    Remove the bush using the SST.

  1. NOTE:
    NOTE:Rear side
    Remove the bush using the SST.

Item 31 : 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 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 35 : Mainshaft rear bearing
  1. Using the SSTs remove the mainshaft rear bearing.

Item 46 : Friction damper
  1. Remove the friction damper using a flathead screwdriver.

Item 54 : 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 56 : 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 58 : 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 74 : 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 79 : Maindrive gear bearing race
  1. Grasping the mainshaft and countershaft, move them forward and back to remove the bearing races.

Item 83 : 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.

Disassembly and Assembly of Subassemblies > < Transmission - 4x2, Vehicles With: 5-Speed Manual Transmission (S15M)-5-Speed Manual Transmission (S15MX)