MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 CLUTCH HOUSING COVER

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  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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  4. REMOVE CLUTCH RELEASE FORK SHAFT OIL SEAL

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  5. REMOVE MANUAL TRANSAXLE DRAIN PLUG


    1. Remove the manual transaxle drain plug and gasket from the manual transmission case.

  6. REMOVE MANUAL TRANSAXLE FILLER PLUG


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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01VJ7B

      Disengage the 2 clamps to disconnect the wire harness connector.

    2. A01VKATE01

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

      SST
      09817-16011

  8. REMOVE CONTROL CABLE BRACKET


    1. A01VJCA

      Remove the 2 bolts and control cable bracket.

  9. REMOVE NEUTRAL POSITION SWITCH (w/ Stop And Start System)


    1. A01VJ1FE01

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

      SST
      09817-16011

  10. REMOVE SHIFT GATE PIN


    1. A01VM6I

      Remove the shift gate pin from the manual transmission case.

  11. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. w/ Stop And Start System:


      1. A01VIVN

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

    2. w/o Stop And Start System:


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

    3. Remove the select return compression spring from the manual transmission case.

  12. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01VEBO

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

  13. 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 from the manual transaxle case.

  14. REMOVE REVERSE IDLER GEAR SHAFT


    1. A01VG1R

      Remove the reverse idler gear shaft from the manual transaxle case.

  15. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


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

  16. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VLIJ

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

  17. 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 a hammer, remove the slotted spring pin from the No. 1 gear shift head.

    3. A01VI61

      Remove No. 1 gear shift fork shaft, No. 1 gear shift head and the No. 1 gear shift fork from manual transaxle case.

    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 the No. 1 gear shift fork shaft.

      Tech Tips

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

  18. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01VKFJ

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

    2. A01VFIT

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

    3. A01VJ9W

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

      Tech Tips

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

    4. A01VH7E

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

    5. A01VLZB

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

      Note

      Do not overtighten the vise.

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

      Tech Tips

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

  19. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A01VEKN

      Using a magnet hand, 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 the No. 2 gear shift fork.

    4. A01VGKQ

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

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

    6. A01VJ2K

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

      Note

      Do not overtighten the vise.

    7. 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.

  20. REMOVE INPUT SHAFT ASSEMBLY


    1. A01VGYH

      Remove the input shaft assembly from the manual transaxle case.

  21. REMOVE OUTPUT SHAFT ASSEMBLY


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

  22. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01VF1Q

      Remove the differential case assembly from the manual transaxle case.

  23. 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.

  24. REMOVE TRANSMISSION MAGNET


    1. A01VGW0

      Remove the transmission magnet from the manual transaxle case.

  25. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01VGHCE04
      Text in Illustration
      *a Protective Tape

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

      Note

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

  26. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01VG69E04

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

      SST
      09308-00010

  27. REMOVE OUTPUT SHAFT COVER


    1. A01VEOO

      Remove the output shaft cover from the manual transaxle case.

  28. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01VGUHE02

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

      SST
      09308-00010

      Note

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

  29. 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 )

  30. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01VLP2E01

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

      SST
      09308-00010

      Note

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

  31. 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 manual transaxle case.

      SST
      09308-00010

  32. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01VHOD

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

  33. REMOVE OUTPUT SHAFT REAR BEARING


    1. A01VKWRE02
      Text in Illustration
      *a Turn
      *b Hold

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

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

  34. REMOVE REAR OUTPUT SHAFT BEARING SHIM


    1. A01VEBL

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