MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. B0047PN

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. B0046VB

      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. B00488H

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (w/ Stop and Start System)


    1. B00476Y

      Using a 27 mm deep socket wrench, remove the park/neutral position switch assembly and gasket from the manual transmission case.

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. B0048A8

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

  6. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  7. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  10. REMOVE CLUTCH TUBE BOOT


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

  11. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  12. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  13. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. B004758E02
      Text in Illustration
      *1 Wooden Blocks

      Place the manual transaxle assembly on wooden blocks.

  14. REMOVE TRANSMISSION CASE PLUG


    1. B0045VI

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

  15. REMOVE TRANSMISSION CASE PLUG (w/o Stop and Start System)


    1. B0046KR

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

  16. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. B0046BB

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

  17. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. B0046BF

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

  18. REMOVE LOCK BALL PIN


    1. B0047P8

      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.

  19. REMOVE SHIFT DETENT BALL


    1. B0047P6

      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. B0046A7

      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.

  20. REMOVE OUTER SHIFT LEVER E RING


    1. B0047WB

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

  21. REMOVE MANUAL TRANSMISSION CASE


    1. B0047KR

      Remove the 16 bolts.

    2. B0045U2E02
      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. B0047HTE03
      Text in Illustration
      *a Boss

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

    4. B00464PE03
      Text in Illustration
      *a Push

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

  22. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. B0047G4

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

  23. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. B0047WL

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

  24. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. B0045WX

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

  25. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. B0045YU

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

    2. B0046T4E01
      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.

  26. REMOVE OUTER SELECT LEVER


    1. B00457YE01
      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.

  27. REMOVE OUTER SELECT LEVER OIL SEAL


    1. B0048B2E02
      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.

  28. REMOVE INPUT SHAFT ASSEMBLY


    1. B0047LL

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

  29. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. B0047OA

      Remove the differential case assembly from the front transaxle case.

  30. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. B00460RE01

      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. B0047KKE12
      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.

  31. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. B0046CXE01

      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. B0047IOE07
      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.

  32. REMOVE TRANSMISSION MAGNET


    1. B0046D4

      Remove the transmission magnet from the front transaxle case.

  33. REMOVE TRANSMISSION OIL SEPARATOR


    1. B0047RB

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

  34. REMOVE BREATHER PLUG


    1. B0046WH

      Remove the breather plug from the front transaxle case.

  35. REMOVE FRONT OUTPUT SHAFT BEARING


    1. B004767E01

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

      SST
      09308-00010
    2. B0046LO

      Remove the output shaft cover from the front transaxle case.

  36. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. B0045T4E01

      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 )

  37. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. B004731

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

  38. REMOVE STRAIGHT PIN


    1. B004811

      Remove the 5 straight pins from the front transaxle case.

  39. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. B0045R6

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

  40. REMOVE INPUT SHAFT COVER


    1. B00455I

      Remove the input shaft cover from the manual transmission case.

  41. REMOVE NO. 1 OIL RECEIVER PIPE


    1. B0045ME

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

  42. REMOVE TRANSMISSION OIL SEPARATOR


    1. B0045HY

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

  43. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. B0046TI

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

  44. REMOVE OUTER NO. 1 SHIFT LEVER


    1. B0045W6E01
      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.

  45. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. B0047IBE03
      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.

  46. REMOVE REAR OUTPUT SHAFT BEARING


    1. B0047I9E01

      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

  47. REMOVE TRANSMISSION CASE OIL SEAL


    1. B0048B4E02

      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 )

  48. REMOVE TRANSAXLE CASE OIL SEAL


    1. B0045V9E01

      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 )