MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  3. REMOVE RELEASE FORK SUPPORT

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  4. REMOVE CLUTCH RELEASE FORK BOOT

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  5. REMOVE CONTROL CABLE BRACKET

    1. C300489

      Remove the 3 bolts and control cable bracket from the manual transmission case.

  6. REMOVE SELECTING BELL CRANK ASSEMBLY

    1. C112480

      Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C112471N01

      Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

      09816-30010

  8. REMOVE NEUTRAL POSITION SWITCH

    1. C202828N01

      Using SST, remove the neutral position switch and gasket from the manual transmission case.

      09816-30010

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C116559

      Remove the No. 1 lock ball assembly from the manual transmission case.

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY

    1. C116599

      Remove the No. 2 lock ball assembly from the manual transmission case.

  11. REMOVE SHIFT GATE PIN

    1. C116598

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY

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  13. REMOVE SHIFT AND SELECT PIN

    1. C328680C01

      *a

      Press and hold

      *b

      Pull out the shift and select pin

      *c

      Protective Tape

      While pressing in the shift and select pin as far as it will go, pull out the shift and select pin to remove it.

      Tip:

      Tape the screwdriver tip before use.

    2. Remove the spring.

  14. REMOVE O-RING

    1. C117500C02

      *1

      O-ring

      *2

      Shift and Select Pin

      Remove the O-ring from the shift and select pin.

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C113635

      Remove the manual transmission filler plug and gasket from the manual transmission case.

  16. REMOVE DRAIN PLUG

    1. C113634

      Remove the drain plug and gasket from the front transaxle case.

  17. REMOVE SHIFT DETENT BALL

    1. C113593C01

      *1

      Shift Detent Ball

      *2

      Spring

      *3

      Spring Seat

      Using a 6 mm hexagon wrench, remove the 4 detent ball plugs from the front transaxle case.

    2. Using a magnet hand, remove the 4 spring seats, 4 springs and 4 shift detent balls from the front transaxle case.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C116545

      Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

  19. REMOVE MANUAL TRANSMISSION CASE PLUG

    1. C275890

      Remove the 2 manual transmission case plugs from the manual transmission case.

  20. REMOVE MANUAL TRANSMISSION CASE

    1. C327698

      Remove the 6 bolts from the manual transmission case.

    2. C327697

      Remove the 12 bolts and manual transmission case from the front transaxle case.

    3. C116542

      Use 2 snap ring pliers to keep the snap ring stretched and remove the manual transmission case.

  21. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C113590

      Remove the No. 1 oil receiver pipe from the manual transmission case.

      Note:

      Do not damage the No. 1 oil receiver pipe.

  22. REMOVE TRANSMISSION OIL SEPARATOR

    1. C275888

      Remove the 2 bolts and transmission oil separator from the manual transmission case.

  23. REMOVE 1ST AND 2ND SHIFT FORK SHAFT

    1. C115434

      Remove the bolt from the No. 1 gear shift fork.

    2. C116327

      Remove the 1st and 2nd shift fork shaft from the front transaxle case.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT

    1. C117839

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

    2. C117840

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

    3. C115438

      Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head from the front transaxle case.

  25. REMOVE NO. 2 GEAR SHIFT FORK

    1. C115439

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT

    1. C115440C01

      *1

      E-ring

      *2

      Pin

      Using a screwdriver, remove the E-ring from the pin.

    2. C115441

      Remove the pin from the shift arm.

    3. C116567

      Remove the shift arm from the No. 5 gear shift fork shaft.

    4. C115442

      Remove the No. 5 gear shift fork shaft from the front transaxle case.

    5. C113585C01

      *1

      No. 3 Gear Shift Head

      *2

      No. 5 Gear Shift Fork Shaft

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 3 gear shift head.

    6. Remove the No. 3 gear shift head from the No. 5 gear shift fork shaft.

  27. REMOVE NO. 1 GEAR SHIFT FORK

    1. C115443

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

  28. REMOVE SHIFT ARM

    1. C116744

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT

    1. C115428

      Remove the bolt from the reverse shift fork shaft.

    2. C115429

      Remove the reverse shift fork shaft from the front transaxle case.

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT

    1. C115430

      Remove the bolt from the No. 3 gear shift fork.

    2. C115431

      Remove the 5th and 6th shift fork shaft from the front transaxle case.

  31. REMOVE NO. 3 GEAR SHIFT FORK

    1. C275889

      Remove the No. 3 gear shift fork from the No. 2 output shaft assembly.

  32. REMOVE REVERSE SHIFT FORK

    1. C115432

      Remove the reverse shift fork from the No. 2 output shaft assembly.

  33. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

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  34. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

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  35. REMOVE REVERSE IDLER GEAR

    1. C275887

      Remove the reverse idler gear shaft by sliding and lifting it.

    2. C275892C01

      *1

      Reverse Idler Gear

      *2

      Needle Roller Bearing

      *3

      Reverse Idler Thrust Washer

      *4

      Reverse Idler Gear Shaft

      Remove the reverse idler gear, needle roller bearing, and reverse idler thrust washer from the reverse idler gear shaft.

  36. REMOVE INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT

    1. C116196

      Remove the input shaft assembly, No. 1 output shaft assembly and No. 2 output shaft assembly at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR

    1. C275912

      Remove the 2 bolts and transmission oil separator from the front transaxle case.

  38. REMOVE DIFFERENTIAL GEAR ASSEMBLY

    1. C115412

      Remove the differential gear assembly from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET

    1. C115449

      Remove the transmission magnet from the front transaxle case.

  40. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE

    1. C113586N02

      Using SST, remove the No. 2 output shaft rear bearing outer race from the manual transmission case.

      09387-00041

      09387-02020

  41. REMOVE OUTPUT SHAFT REAR BEARING SHIM

    1. C116565

      Remove the output shaft rear bearing shim from the manual transmission case.

  42. REMOVE SHIFT FORK SHAFT BEARING

    1. C113594N03

      Using SST, remove the 4 shift fork shaft bearings from the manual transmission case.

      09612-65014

      09387-00041

      09387-01021

      09527-20011

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

    1. C113581N01

      Using SST, remove the shift and select lever shaft needle roller bearing from the manual transmission case.

      09612-65014

      09387-00041

      09387-01021

  44. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING

    1. C116544C01

      *1

      Input Shaft Rear Bearing Shaft Snap Ring

      *2

      Output Shaft Rear Bearing Shaft Snap Ring

      Using snap ring pliers, remove the input shaft rear bearing shaft snap ring from the manual transmission case.

    2. Using snap ring pliers, remove the output shaft rear bearing shaft snap ring from the manual transmission case.

  45. REMOVE INPUT SHAFT FRONT BEARING

    1. C113584

      Remove the bolt from the front transaxle case.

    2. C113580N02

      Using SST, remove the input shaft front bearing from the front transaxle case.

      09612-30012

  46. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C328684C01

      *a

      Protective Tape

      Using a screwdriver, remove the front transaxle case oil seal from the front transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  47. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE

    1. C328683C01

      *a

      Turn

      *b

      Hold

      Using SST, remove the No. 2 output shaft front bearing outer race from the front transaxle case.

      09387-00041

      09387-02020

  48. REMOVE OUTPUT SHAFT COVER

    1. C300492

      Remove the output shaft cover from the front transaxle case.

  49. REMOVE OUTPUT SHAFT FRONT BEARING

    1. C328681

      Remove the bolt from the front transaxle case.

    2. C113597N01

      Using SST, remove the output shaft front bearing from the front transaxle case.

      09612-65014

      09612-01020

  50. REMOVE OUTPUT SHAFT COVER

    1. C328682

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING

    1. C113595N01

      Using SST, remove the 4 shift fork shaft bearings from the front transaxle case.

      09612-65014

      09387-00041

      09387-01021

  52. REMOVE TRANSMISSION CASE OIL SEAL

    1. C116195

      Using a screwdriver, remove the transmission case oil seal from the manual transmission case.

      Tip:

      Tape the screwdriver tip before use.

  53. REMOVE FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE

    1. C116548

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

  54. REMOVE TRANSAXLE CASE OIL SEAL

    1. C116194

      Using a screwdriver, remove the transaxle case oil seal from the front transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  55. REMOVE FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE

    1. C113588N01

      Using SST, remove the front differential case front bearing outer race from the front transaxle case.

      09387-00041

      09387-02020