MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  2. REMOVE CLUTCH RELEASE FORK LEVER

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  3. REMOVE MANUAL TRANSAXLE CASE PLUG


    1. A01VJ6J

      Remove the manual transaxle case plug and gasket from the manual transaxle case.

  4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01VJ7B

      Disengage the 2 clamps and disconnect the wire harness connector.

    2. A01VKATE01

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

      SST
      09817-16011

  5. REMOVE CONTROL CABLE BRACKET


    1. A01VJCA

      Remove the 2 bolts and the control cable bracket.

  6. REMOVE SHIFT GATE PIN


    1. A01VM6I

      Remove the shift gate pin from the manual transmission case.

  7. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01VIES

      Remove the 4 bolts and shift and select lever shaft assembly from the transmission case.

    2. Remove the select return compression spring from the transmission case.

  8. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01VEBO

      Remove the reverse idler gear shaft bolt and gasket.

  9. REMOVE MANUAL TRANSMISSION CASE


    1. A01VH42

      Remove the 5 bolts from the manual transaxle case side.

    2. A01VLLQ

      Remove the 8 bolts from the manual transmission case side.

    3. Using a plastic hammer, remove the manual transmission case.

  10. REMOVE REVERSE IDLER GEAR SHAFT


    1. A01VG1R

      Remove the reverse idler gear shaft from the transaxle case.

  11. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. Remove the reverse idler gear sub-assembly from the transaxle case.

  12. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VLIJ

      Remove the 2 bolts and the reverse shift arm bracket assembly from the front transaxle case.

  13. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A01VGIE

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

    2. A01VHGG

      Using a pin punch and hammer, remove the slotted spring pin from No. 1 gear shift head.

    3. A01VI61

      Remove No. 1 gear shift fork shaft, No. 1 gear shift head and No. 1 gear shift fork.

    4. A01VGKL

      Hold the No. 1 gear shift fork shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    5. Using 2 screwdrivers and a hammer, remove the snap ring from No. 1 gear shift fork shaft.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

  14. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01VKFJ

      Remove the straight pin from No. 3 gear shift fork.

    2. A01VFIT

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

    3. A01VJ9W

      Using 2 screwdrivers and a hammer, remove the snap ring from No. 3 gear shift fork shaft.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

    4. A01VH7E

      Remove No. 3 gear shift fork shaft, the compression spring, No. 3 gear shift head and No. 3 gear shift fork from the front transaxle case.

    5. Hold the No. 3 gear shift fork shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    6. A01VLZB

      Using 2 screwdrivers and a hammer, remove the snap ring from No. 3 gear shift fork shaft.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

  15. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01VEKN

      Using a magnetic finger, remove the straight pin from the reverse shift fork.

    2. A01VHXW

      While lifting the reverse shift fork, using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

    3. A01VGFP

      Remove the bolt from No. 2 gear shift fork.

    4. A01VGKQ

      Shift the No. 2 gear shift fork and No. 2 transmission clutch hub sleeve to the 4th gear position.

    5. Remove No. 2 gear shift fork shaft, No. 2 gear shift fork and the reverse shift fork.

    6. Hold the No. 2 gear shift fork shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    7. A01VJ2K

      Using 2 screwdrivers and a hammer, remove the snap ring from No. 2 gear shift fork shaft.

      Tech Tips

      Use a piece of cloth to prevent the snap ring from flying off.

  16. REMOVE INPUT SHAFT ASSEMBLY


    1. A01VGYH

      Remove the input shaft assembly from the manual transaxle case.

  17. REMOVE OUTPUT SHAFT ASSEMBLY


    1. Remove the output shaft assembly from the manual transaxle case.

  18. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01VF1Q

      Remove the differential case assembly from the front transaxle case.

  19. REMOVE NO. 2 OIL RECEIVER PIPE


    1. A01VF00

      Remove the No. 2 oil receiver pipe from the manual transmission case.

      Note

      Do not damage No. 2 oil receiver pipe.

  20. REMOVE TRANSMISSION MAGNET


    1. A01VGW0

      Remove the transmission magnet from the front transaxle case.

  21. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01VGHC

      Using a screwdriver with its tip wrapped with protective tape, pry out the front transaxle case oil seal.

      Note

      Do not damage the installation surfaces of the front transaxle case.

  22. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01VG69E04

      Using SST, remove the output shaft front bearing (outer race) from the front transaxle case.

      SST
      09308-00010

  23. REMOVE OUTPUT SHAFT COVER


    1. A01VEOO

      Remove the output shaft cover from the transaxle case.

  24. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01VGUHE02

      Using SST, remove the transmission case oil seal from the manual transaxle case.

      SST
      09308-00010

      Note

      Do not damage the installation surfaces of the manual transmission case.

  25. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VJB5E05

      Using SST, remove the front differential case rear tapered roller bearing outer race and differential case shim from the manual transmission case.

      SST
      09950-60010   ( 09951-00560 )
      09950-70010   ( 09951-07200 )

  26. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01VLP2E01

      Using SST, remove the transaxle case oil seal from the transaxle case.

      SST
      09308-00010

      Note

      Do not damage the installation surfaces of the front transaxle case.

  27. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VLCHE01

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

      SST
      09308-00010

  28. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01VHOD

      Remove the rear input shaft bearing shim from the transmission case.

  29. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01VH1SE03

      Using SST, remove the rear output shaft bearing outer race from the manual transmission case.

      SST
      09527-30010
      09612-65014   ( 09612-01030, 09612-01050 )

  30. REMOVE REAR OUTPUT SHAFT BEARING SHIM


    1. A01VEBL

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