MANUAL TRANSAXLE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

  • When the front differential case front tapered roller bearing (outer race) is removed, the front differential case front tapered roller bearing and front differential case front tapered roller bearing (outer race) need to be replaced.

  • When the front differential case front tapered roller bearing (outer race) is removed, the front differential case front tapered roller bearing and front differential case front tapered roller bearing (outer race) can be reused.

  • When the front differential case rear tapered roller bearing (outer race) is removed, the front differential case rear tapered roller bearing and front differential case rear tapered roller bearing (outer race) need to be replaced.

  • When the front differential case rear tapered roller bearing (outer race) is removed, the front differential case rear tapered roller bearing and front differential case rear tapered roller bearing (outer race) can be reused.

PROCEDURE

  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  3. REMOVE CLUTCH RELEASE FORK BOOT

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  4. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

    1. C305410

      Using a 6 mm hexagon wrench, remove the bolt and speedometer driven hole cover sub-assembly from the No. 1 transaxle (MTM) case.

    2. Remove the O-ring from the speedometer driven hole cover sub-assembly.

  5. REMOVE CLUTCH BUFFER GUIDE BUSH

    1. C304102

      Remove the 3 bolts and clutch buffer guide bush from the No. 1 transaxle (MTM) case.

  6. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C304103

      Using a 22 mm deep socket wrench, remove the back-up light switch assembly from the manual transmission case.

  7. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C304104

      Using a 27 mm socket wrench, remove the manual transmission filler plug from the manual transmission case.

  8. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY

    1. C304105

      Using a 7 mm square wrench, remove the drain (MTM) plug sub-assembly and drain plug (MTM) gasket from the manual transmission case.

  9. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY

    1. C304106

      Remove the 3 bolts and manual transmission case cover sub-assembly with manual transmission case cover gasket from the manual transmission case.

    2. Remove the manual transmission case cover gasket from the manual transmission case cover sub-assembly.

  10. REMOVE NO. 3 TRANSMISSION CLUTCH HUB WITH NO. 3 TRANSMISSION HUB SLEEVE

    1. C304107

      Using a 5 mm pin punch and a hammer, remove the pin from the No. 3 shift fork.

    2. C304108

      Using a snap ring expander, remove the No. 3 transmission clutch hub shaft snap ring from the output shaft assembly.

    3. C304109

      Remove the spacer from the output shaft assembly.

    4. C304110

      Remove the No. 3 shift fork and No. 3 transmission clutch hub with No. 3 transmission hub sleeve from the output shaft assembly.

  11. REMOVE NO. 2 SYNCHRONIZER RING SET

    1. C305948

      Remove the No. 2 synchronizer ring set from the 5th driven gear.

  12. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

    1. C306366C02

      *a

      Matchmark

      Put matchmarks on the No. 3 transmission clutch hub and No. 3 transmission hub sleeve.

    2. Remove the No. 3 transmission clutch hub, 3 No. 2 synchromesh shifting keys, 3 synchromesh shifting key balls and 3 compression springs from the No. 3 transmission hub sleeve.

      Note:

      Pay attention to prevent the synchromesh shifting key balls and compression springs from scattering.

      C305947C02

      *1

      No. 3 Transmission Hub Sleeve

      *2

      No. 3 Transmission Clutch Hub

      *3

      No. 2 Synchromesh Shifting Key

      *4

      Compression Spring

      *5

      Synchromesh Shifting Key Ball

      -

      -

  13. REMOVE 5TH DRIVEN GEAR

    1. C305949

      Remove the 5th driven gear from the output shaft assembly.

  14. REMOVE 5TH GEAR

    1. C304111

      Using a snap ring expander, remove the 5th gear shaft snap ring from the input shaft assembly.

    2. C304112

      Remove the 5th gear thrust washer from the input shaft assembly.

    3. C304113N01

      Using SST, remove the 5th gear from the input shaft assembly.

      09950-40011

  15. REMOVE REAR (MTM) BEARING RETAINER

    1. C304114

      Using a T40 "TORX" socket wrench, remove the 4 bolts.

    2. Remove the rear (MTM) bearing retainer (for input shaft assembly) and rear (MTM) bearing retainer (for output shaft assembly) from the manual transmission case.

  16. REMOVE MANUAL TRANSMISSION CASE

    1. C304115

      Remove the 17 bolts and manual transmission case from the No. 1 transaxle (MTM) case.

  17. REMOVE REVERSE IDLER GEAR SHAFT

    1. C304116

      Remove the reverse idler gear shaft from the No. 1 transaxle (MTM) case.

  18. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C305343

      Remove the reverse idler gear sub-assembly from the No. 2 transaxle (MTM) case.

  19. REMOVE REVERSE SHIFT ARM

    1. C304117

      Remove the No. 1 reverse shift arm pin from the reverse shift arm.

    2. C304118

      Remove the reverse shift arm.

  20. REMOVE SHIFT AND SELECT LEVER SUB-ASSEMBLY

    1. C304119N01

      Move the shift and select lever sub-assembly to the 2nd gear position as indicated by the arrows, in the order shown in the illustration.

    2. C304120

      Using a 5 mm pin punch and a hammer, remove the shift and select lever shaft straight pin from the shift and select lever sub-assembly.

    3. C304121

      Remove the shift and select lever from the No. 2 transaxle (MTM) case.

    4. C305401

      Remove the shift and select arm from the No. 2 transaxle (MTM) case.

  21. REMOVE SHIFT AND SELECT LEVER SHAFT DUST BOOT

    1. C305403

      Remove the shift and select lever shaft dust boot from the shift and select lever.

  22. REMOVE SHIFT AND SELECT LEVER SHAFT SPRING

    1. C305402

      Remove the shift and select lever shaft spring.

  23. REMOVE SHIFT INTER LOCK PLATE

    1. C304124

      Remove the shift inter lock plate from the No. 2 transaxle (MTM) case.

  24. REMOVE INPUT SHAFT ASSEMBLY AND OUTPUT SHAFT ASSEMBLY

    1. C304125

      Remove the gear-box control lever spring from the No. 3 gear shift fork.

    2. C305407

      Remove the input shaft assembly, output shaft assembly, No. 2 gear shift fork and No. 3 gear shift fork from the transaxle (MTM) case sub-assembly.

  25. REMOVE NO. 2 GEAR SHIFT FORK

    1. Remove the No. 2 gear shift fork from the input shaft assembly.

  26. REMOVE NO. 3 GEAR SHIFT FORK

    1. Remove the No. 3 gear shift fork from the output shaft assembly.

  27. REMOVE NO. 1 GEAR SHIFT FORK

    1. C304142

      Remove the shift fork shaft E ring from the No. 3 gear shift fork.

    2. Remove the No. 1 gear shift fork from the No. 3 gear shift fork shaft.

  28. REMOVE NO. 2 SHIFT FORK

    1. C304141

      Using a 5 mm pin punch and a hammer, remove the pin from the No. 2 gear shift fork.

    2. Remove the No. 2 shift fork from the No. 2 gear shift fork shaft.

  29. REMOVE NO. 2 TRANSAXLE (MTM) CASE

    1. C304128

      Using a T50 "TORX" socket wrench, remove the 11 bolts and No. 2 transaxle (MTM) case from the No. 1 transaxle (MTM) case.

  30. REMOVE TRANSMISSION MAGNET

    1. C304129

      Remove the transmission magnet from the No. 1 transaxle (MTM) case.

  31. REMOVE NO. 2 REVERSE SHIFT ARM PIN

    1. C304130

      Remove the No. 2 reverse shift arm pin from the No. 1 transaxle (MTM) case.

    2. Remove the spring from the No. 1 transaxle (MTM) case.

  32. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C304131

      Remove the differential case assembly from the No. 1 transaxle (MTM) case.

  33. REMOVE REVERSE SHIFT ARM BRACKET

    1. C305408

      Using a drill bit, drill out the rivet head and remove the reverse shift arm bracket.

      Note:

      • Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.

      • Be careful as the cut rivet will be very hot.

  34. REMOVE NO. 1 SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

    1. C306247N01

      Using SST, remove the No. 1 shift and select lever shaft needle roller bearing from the No. 2 transaxle (MTM) case.

      0317-MAZ

      0317-AQ

  35. REMOVE NO. 2 SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

    1. C306248N01

      Using SST, remove the No. 2 shift and select lever shaft needle roller bearing from the No. 2 transaxle (MTM) case.

      0317-MAZ

      0317-AQ

  36. REMOVE BREATHER PROTECTOR

    1. C305404

      Disengage the 4 claws and remove the breather protector from the breather plug.

  37. REMOVE BREATHER PLUG

    1. C304136

      Remove the breather plug from the manual transmission case.

  38. REMOVE NO. 1 MANUAL TRANSMISSION CASE STRAIGHT PIN

    1. C304137

      Using pliers, remove the 3 No. 1 manual transmission case straight pins from the No. 1 transaxle (MTM) case.

  39. REMOVE NO. 2 MANUAL TRANSMISSION CASE STRAIGHT PIN

    1. C306397

      Using pliers, remove the 2 No. 2 manual transmission case straight pins from the No. 1 transaxle (MTM) case.

  40. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

    1. C304134N01

      Using SST, remove the front drive shaft oil seal LH from the manual transmission case.

      09308-00010

      Note:

      Be careful not to damage the installation surfaces of the manual transmission case.

  41. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)

    1. C304135

      Using a brass bar and a hammer, remove the front differential case rear tapered roller bearing (outer race) from the manual transmission case.

      Note:

      Do not damage or deform the front differential case rear tapered roller bearing (outer race) (when reusing the front differential case rear tapered roller bearing (outer race)).

  42. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

    1. C304132N01

      Using SST, remove the front drive shaft oil seal RH from the No. 1 transaxle (MTM) case.

      09308-00010

      Note:

      Be careful not to damage the installation surfaces of the No. 1 transaxle (MTM) case.

  43. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)

    1. C304133

      Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the No. 1 transaxle (MTM) case.

      Note:

      Do not damage or deform the front differential case front tapered roller bearing (outer race) (when reusing the front differential case front tapered roller bearing (outer race)).