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MANUAL TRANSAXLE UNIT DISASSEMBLY

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PROCEDURE


  1. Click here

    REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01VLJM

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

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    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.

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    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.

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    REMOVE NEUTRAL POSITION SWITCH (w/ Stop and Start System)


    1. A01VF4P

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

  5. Click here

    REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A01VI5J

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

  6. Click here

    REMOVE WIRE HARNESS CLAMP BRACKET (w/ Stop and Start System)


    1. A01VLR9

      Remove the bolt and wire harness clamp bracket from the manual transmission case.

  7. Click here

    REMOVE NO. 1 CLUTCH HOUSING COVER

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  8. Click here

    REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  9. Click here

    REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  10. Click here

    REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  11. Click here

    REMOVE CLUTCH TUBE BOOT


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

  12. Click here

    REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

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    REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

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    SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A01VDUZE04

      Place the manual transaxle assembly on wooden blocks.

      Table 1. Text in Illustration
      *a Wooden Block
  15. Click here

    REMOVE TRANSMISSION CASE PLUG


    1. A01VFD8

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

  16. Click here

    REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01VI4Y

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

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    REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01VINS

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

  18. Click here

    REMOVE LOCK BALL PIN


    1. A01VH3E

      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 lock ball pin from the manual transmission case.

  19. Click here

    REMOVE SHIFT DETENT BALL


    1. A01VGWF

      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 shift detent ball from the manual transmission case.

    3. A01VG7K

      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 2 shift detent balls from the manual transmission case.

  20. Click here

    REMOVE OUTER SHIFT LEVER E-RING


    1. A01VI72

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

  21. Click here

    REMOVE MANUAL TRANSMISSION CASE


    1. A01VLIA

      Remove the 16 bolts.

    2. A01VKRYE02

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

      Table 2. Text in Illustration
      *a Protective Tape
      Note:

      Do not damage the manual transmission case.

    3. A01VM8EE01

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

      Table 3. Text in Illustration
      *a Boss
    4. A01VKJZ

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

  22. Click here

    REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01VF4O

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

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    REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01VHZ5

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

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    REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VFNG

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

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    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

      Turn the shift and select lever shaft assembly and shift interlock plate clockwise and remove them from the front transaxle case.

      Table 4. Text in Illustration
      *1 Shift and Select Lever Shaft Assembly
      *2 Shift Interlock Plate
  26. Click here

    REMOVE OUTER SELECT LEVER


    1. A01VKRME02

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

      Table 5. Text in Illustration
      *1 Inner Select Lever
      *2 Outer Select Lever
  27. Click here

    REMOVE OUTER SELECT LEVER OIL SEAL


    1. A01VL34E05

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

      Table 6. Text in Illustration
      *a Protective Tape
      Note:

      Do not damage the installation surfaces.

  28. Click here

    REMOVE INPUT SHAFT ASSEMBLY


    1. A01VJCF

      Remove the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly from the front transaxle case.

  29. Click here

    REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A01VI6B

      Remove the front differential case assembly from the front transaxle case.

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    REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VE60E03

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

      09308-00010
    2. A01VGQ4E12

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

      Table 7. Text in Illustration
      *a Hold
      *b Turn
      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. Click here

    REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VLOAE01

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

      09308-00010
    2. A01VFK4E10

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

      Table 8. Text in Illustration
      *a Hold
      *b Turn
      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. Click here

    REMOVE TRANSMISSION MAGNET


    1. A01VF8W

      Remove the transmission magnet from the front transaxle case.

  33. Click here

    REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VK8U

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

  34. Click here

    REMOVE BREATHER PLUG


    1. A01VHX6

      Remove the breather plug from the front transaxle case.

  35. Click here

    REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)


    1. A01VI74E03

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

      09308-00010
    2. A01VHS6

      Remove the output shaft cover from the front transaxle case.

  36. Click here

    REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01VE04E03

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

      09950-60010 09951-00360
      09950-70010 09951-07150
  37. Click here

    REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01VFTU

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

  38. Click here

    REMOVE STRAIGHT PIN


    1. A01VG0Q

      Remove the 5 straight pins from the front transaxle case.

  39. Click here

    REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01VJD6

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

  40. Click here

    REMOVE INPUT SHAFT COVER


    1. A01VF4G

      Remove the input shaft cover from the manual transmission case.

  41. Click here

    REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01VKKV

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

  42. Click here

    REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VM83

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

  43. Click here

    REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A01VKTA

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

  44. Click here

    REMOVE OUTER NO. 1 SHIFT LEVER


    1. A01VEDYE01

      Using a 5 mm pin punch and a hammer, remove the inner shift lever slotted spring pin from the inner No. 1 shift lever.

      Table 9. Text in Illustration
      *1 Inner No. 1 Shift Lever
      *2 Outer Shift Lever Spacer
      *3 Outer No. 1 Shift Lever
      Tip:

      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 outer No. 1 shift lever from the manual transmission case.

  45. Click here

    REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A01VJ8XE06

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

      Table 10. Text in Illustration
      *a Protective Tape
      Note:

      Do not damage the installation surfaces.

  46. Click here

    REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)


    1. A01VJBGE04

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

      09308-00010
  47. Click here

    REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. A01VH0XE02

      Using SST and a hammer, remove the front drive shaft oil seal LH from the manual transmission case.

      09950-60010 09951-00620
      09950-70010 09951-07150
  48. Click here

    REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. A01VJWQE02

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

      09950-60010 09951-00530
      09950-70010 09951-07150