Gen 4, 09, Transmission removal problems

prodiver

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For over a week now I have been trying to remove the transmission in my 09 to replace the slave cylinder and clutch. I have followed the service manual word for word and have not been able to get it out. I cannot get the last inch or so to clear the clutch because the bell housing is to large to clear the transmission tunnel. If I drop it down slightly it binds on the clutch and motor. If I raise it up slightly it binds on both the sides and top. Unlike the Gen 3 tranny that the transmission can be serviced by just removing the trans. from the bell housing the TR6060 says to remove the Bell housing to service tranny. I am at a loss about what to do. Either try to enlarge the trans. tunnel or grind some of the sides off the bell housing. Has anyone else had this problem?
 

Steve M

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I've always found it to be a delicate process, but definitely doable with the clutches I've used (OEM, McLeod RST, and Nth Moto Triple Carbon).

As soon as the input shaft clears the pressure plate fingers, you have to start lowering the transmission immediately...it will not clear if you keep pulling it straight out.

The next obstacle should be the bell housing...again, as soon as the input shaft clears that, you'll have to start lowering it again.

It just barely clears, but it should do so without having to grind anything.
 

Steve M

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Oh, and one more thing...I don't think it is possible to remove the bellhousing from the tunnel without rotating it 90 degrees and letting it come straight down, at least not that I've found.
 

99RT10GTS

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DO NOT TRY TO REMOVE THE TRANSMISSION ALL IN ONE UNIT!!!!

You have to get the 8 bolts removing the trans FROM the bellhousing FIRST!!!
 
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prodiver

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I know that on the Gen 3 that has the T56 transmission that you have to remove the transmission and then the bell housing. On the T56 the slave cylinder is part of the transmission. On the Gen 4 the slave cylinder is in the bell housing. Another problem I have found is that
on the top of the bell housing there are wires that are attached to it and there is no way to get them loose. Can't reach up and cut the wire holders. Can I remove the transmission from the bell housing without causing any problems. Any help would be much appreciated. I have done quite a few trannys but nothing has given me as much problems as this on.
 

99RT10GTS

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The trans is removed exactly the same way as the G3. The slave is mounted the exact same as the G3. DO NOT OVER THINK IT.
 
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