MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01VLJM

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A01VGH8

      Using a 10 mm hexagon socket wrench, remove the manual transmission drain plug and gasket from the front transaxle case.

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01VFKP

      Using a 27 mm deep socket wrench, remove the back-up light switch assembly and gasket from the manual transmission case.

  4. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A01VDQ6

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

  5. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


    1. Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG


    1. Remove the release cylinder bleeder plug from the clutch release bleeder sub-assembly.

  9. REMOVE CLUTCH TUBE BOOT


    1. Remove the clutch tube boot from the front transaxle case.

  10. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  11. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  12. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A01VJKME02
      Text in Illustration
      *1 Wooden Blocks

      Place the manual transaxle assembly on wooden blocks.

  13. REMOVE TRANSMISSION CASE PLUG


    1. A01VJZX

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

  14. REMOVE TRANSMISSION CASE PLUG


    1. A01VHCB

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

  15. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01VFBW

      Using a 24 mm deep socket wrench, remove the No. 1 lock ball assembly from the manual transmission case.

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01VITH

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

  17. REMOVE LOCK BALL PIN


    1. A01VLWS

      Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.

    2. Using a magnet hand, remove the shift and select lever shaft compression spring and the lock ball pin from the manual transmission case.

  18. REMOVE SHIFT DETENT BALL


    1. A01VH18

      Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the manual transmission case.

    2. Using a magnet hand, remove the shift detent ball compression spring and the shift detent ball from the manual transmission case.

    3. A01VK5S

      Using a 6 mm hexagon socket wrench, remove the 2 shift detent ball plugs from the manual transmission case.

    4. Using a magnet hand, remove the 2 shift detent ball compression springs and the 2 shift detent balls from the manual transmission case.

  19. REMOVE OUTER SHIFT LEVER E RING


    1. A01VJ3X

      Remove the outer shift lever E ring from the outer No. 1 shift lever.

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01VLIA

      Remove the 16 bolts.

    2. A01VLVJE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, separate the manual transmission case from the front transaxle case.

      Note

      Do not damage the manual transmission case.

    3. A01VFEOE03
      Text in Illustration
      *a Boss

      Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.

    4. A01VHU7E03
      Text in Illustration
      *a Push

      Push the outer No. 1 shift lever and remove the manual transmission case.

  21. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01VF4O

      Remove the reverse idler gear shaft, reverse idler thrust washer and the reverse idler gear sub-assembly from the front transaxle case.

  22. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01VHZ5

      Turn the reverse shift fork shaft assembly clockwise and remove it from the front transaxle case.

  23. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VFNG

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

  24. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01VGWP

      Using a 6 mm hexagon socket wrench, remove the inner select lever set bolt.

    2. A01VFJXE01
      Text in Illustration
      *1 Shift and Select Lever Shaft Assembly
      *2 Shift Inter Lock Plate

      Turn the shift and select lever shaft assembly clockwise and remove it and the shift inter lock plate from the front transaxle case.

  25. REMOVE OUTER SELECT LEVER


    1. A01VKRME02
      Text in Illustration
      *1 Inner Select Lever
      *2 Outer Select Lever

      Remove the outer select lever and the inner select lever from the front transaxle case.

  26. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A01VL34E02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the outer select lever oil seal from the front transaxle case.

      Note

      Do not damage the installation surfaces.

  27. REMOVE INPUT SHAFT ASSEMBLY


    1. A01VJCF

      Remove the input shaft assembly, output shaft assembly and the 3 gear shift fork shaft assemblies from the front transaxle case.

  28. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01VI6B

      Remove the differential case assembly from the front transaxle case.

  29. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VE60E01

      Using SST, remove the front differential case front tapered roller bearing (outer race) and the front differential case front plate washer from the front transaxle case.

      SST
      09308-00010
    2. A01VGQ4E12
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the front differential case front tapered roller bearing from the differential case assembly.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00390 )

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  30. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VLOAE01

      Using SST, remove the front differential case rear tapered roller bearing (outer race) and the front differential case rear plate washer from the manual transmission case.

      SST
      09308-00010
    2. A01VFK4E07
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the front differential case rear tapered roller bearing from the front differential case.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00390 )

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  31. REMOVE TRANSMISSION MAGNET


    1. A01VF8W

      Remove the transmission magnet from the front transaxle case.

  32. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VK8U

      Remove the 4 bolts and the transmission oil separator from the front transaxle case.

  33. REMOVE BREATHER PLUG


    1. A01VHX6

      Remove the breather plug from the front transaxle case.

  34. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A01VI74E01

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

      SST
      09308-00010
    2. A01VHS6

      Remove the output shaft cover from the front transaxle case.

  35. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01VE04E01

      Using SST and a hammer, remove the front transaxle case oil seal from the front transaxle case.

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07150 )

  36. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01VFTU

      Remove the reverse restrict pin assembly from the front transaxle case.

  37. REMOVE STRAIGHT PIN


    1. A01VG0Q

      Remove the 5 straight pins from the front transaxle case.

  38. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01VJD6

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

  39. REMOVE INPUT SHAFT COVER


    1. A01VF4G

      Remove the input shaft cover from the manual transmission case.

  40. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01VKKV

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

  41. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VM83

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

  42. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A01VJZH

      Remove the 4 bolts and the manual transmission oil separator sub-assembly from the manual transmission case.

  43. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A01VFEKE01
      Text in Illustration
      *1 Inner No. 1 Shift Lever
      *2 Outer No. 1 Shift Lever

      Using a 5 mm pin punch and a hammer, remove the inner shift lever slotted spring pin.

      Tech Tips

      When removing the inner shift lever slotted spring pin, align the pin with the hole in the No. 1 lock ball assembly.

    2. Remove the inner No. 1 shift lever, outer shift lever spacer and the outer No. 1 shift lever from the manual transmission case.

  44. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A01VJ8XE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the outer shift lever oil seal from the manual transmission case.

      Note

      Do not damage the installation surfaces.

  45. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01VJBGE04

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

      SST
      09308-00010

  46. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01VH0XE01

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

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07150 )

  47. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01VJWQE01

      Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.

      SST
      09950-60010   ( 09951-00530 )
      09950-70010   ( 09951-07150 )