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

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41–8
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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 41–9
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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
(a) Remove the 4 bolts.
(b) Remove the shift lever retainer from the transfer adapter.

D29034

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41–10
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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
(a) Remove the 10 bolts.

D29033

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 41–11
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

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41–12
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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

 41–13
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

21. REMOVE FRONT BEARING RETAINER

(a) Remove the 8 bolts.

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
the transmission case.

D25953

24. REMOVE COUNTER GEAR FRONT BEARING SNAP

RING NO. 1
(a) Using a snap ring expander, remove the snap ring from
the transmission case.

D25954

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41–14
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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

 41–15
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

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41–16
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

30. REMOVE SHIFT FORK SHAFT NO. 1

(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft No. 1.
NOTICE:
Use a cloth to prevent the snap ring from flying off.

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

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 41–17
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

31. REMOVE SHIFT FORK SHAFT NO. 3

(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:
Use a cloth to prevent the snap ring from flying off.

D29057

(c) Remove the shift fork No. 3 and shift fork shaft No. 3 from
the intermediate plate.

D29058

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

41–18
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

32. REMOVE SHIFT FORK SHAFT NO. 4

(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft No. 4.
NOTICE:
Use a cloth to prevent the snap ring from flying off.

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

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

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

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

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41–20
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the counter gear.

D25993

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

 41–21
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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41–22
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

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

 41–23
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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
(a) Using a snap ring expander, remove the snap ring from
the output shaft.

D29064

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

41–24
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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

 41–25
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

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

41–26
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

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

 41–27
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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
the intermediate plate.
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

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

41–28
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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

 41–29
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

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

41–30
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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.)

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

 41–31
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)

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

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

41–32
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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

83. INSTALL SHIFT FORK SHAFT NO. 3

(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

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

 41–33
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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

84. INSTALL SHIFT FORK SHAFT NO. 1

(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

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

41–34
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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.
Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf)

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

85. INSTALL SHIFT FORK SHAFT NO. 2

(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

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

 41–35
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(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.
Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf)

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
to the intermediate plate.

D33570

(b) Using a T40 torx socket wrench, install the 3 spring seat
to the intermediate plate.
Torque: 18.5 N⋅m (190 kgf⋅cm, 14 ft⋅lbf)

D33569

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

41–36
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

(c) Install the detent ball and low side compression spring to
the intermediate plate.

D25960

(d) Using a T40 torx socket wrench, install the spring seat
to the intermediate plate.
Torque: 18.5 N⋅m (190 kgf⋅cm, 14 ft⋅lbf)

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

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 41–37
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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.
Torque: 16.5 N⋅m (170 kgf⋅cm, 12 ft⋅lbf)
(c) Check that the input shaft and output shaft rotate smooth-
ly.

D25950

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

41–38
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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.
Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)

D29040

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 41–39
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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:
Part No. 08826–00090, THREE BOND 1281 or equiva-
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.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)

D29033

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41–40
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

99. R151:
INSTALL EXTENSION HOUSING
(a) Apply seal packing to the extension housing as shown in
the illustration.
Seal
Seal packing:
Packing
Part No. 08826–00090, THREE BOND 1281 or equiva-
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.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)

B85186

(f) Install the shift lever housing bolt to the shift lever hous-
ing.
Torque: 33 N⋅m (340 kgf⋅cm, 25 ft⋅lbf)

G34547

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

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

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.
Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)

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.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)

D29034

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41–42
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)
(c) R151:
Install the 6 bolts.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)

R151

D29032
B85189

D33417

R151F White
104. INSTALL RESTRICT PIN
(a) Install the 2 restrict pins.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
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
Torque: 44 N⋅m (450 kgf⋅cm, 32 ft⋅lbf)

SST
D29030

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

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

106. INSTALL CLUTCH HOUSING

(a) Install the clutch housing to the transmission case with
the 9 bolts.
Torque: 36 N⋅m (370 kgf⋅cm, 27 ft⋅lbf)

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.
Torque: 47 N⋅m (480 kgf⋅cm, 35 ft⋅lbf)

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

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

41–44
MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSMISSION ASSY (R151F, R151)

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.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)

D29024

112. INSTALL FILLER PLUG

(a) Install a new gasket and filler plug to the transmission
case.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)

D29023

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