MULTI-MODE MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01VJY6

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A01VHIV

      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 TRANSMISSION REVOLUTION SENSOR


    1. A01VI1N

      Remove the bolt and the transmission revolution sensor from the manual transmission case.

    2. Remove the O-ring from the transmission revolution sensor.

  5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01VF4P

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

  6. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A01VH7JE01
      Text in Illustration
      *1 Wire Harness Clamp Bracket

      Remove the 6 bolts and the wire harness clamp bracket.

    2. A01VFSXE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the shift and select actuator assembly from the manual transmission case.

      Note

      Do not damage the manual transmission case.

  7. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  8. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  10. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  11. REMOVE CLUTCH TUBE BOOT


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

  12. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  13. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  14. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A01VJFIE03
      Text in Illustration
      *1 Wooden Blocks

      Place the manual transaxle assembly on wooden blocks.

  15. REMOVE TRANSMISSION CASE PLUG


    1. A01VHV2

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

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01VI7U

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

  17. REMOVE SHIFT DETENT BALL


    1. A01VL1M

      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. A01VDV9

      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.

  18. REMOVE MANUAL TRANSMISSION CASE


    1. A01VLIA

      Remove the 16 bolts.

    2. A01VGU2E02
      Text in Illustration
      *1 Protective Tape

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

      Note

      Do not damage the manual transmission case.

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01VFFQ

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01VFW8

      Turn the reverse shift fork shaft assembly clockwise.

    2. A01VGM6

      Remove the reverse shift fork shaft assembly from the front transaxle case.

  21. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VHVW

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01VFQ8

      Turn the shift and select lever shaft assembly clockwise.

    2. A01VGVN

      Remove the shift and select lever shaft assembly from the front transaxle case.

  23. REMOVE INNER NO. 2 SHIFT LEVER


    1. A01VJXI

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin and the inner No. 2 shift lever from the shift and select lever shaft.

      Tech Tips

      Check the orientation of the inner No. 2 shift lever.

  24. REMOVE FRONT INNER SHIFT LEVER


    1. A01VJ3Z

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

      Tech Tips

      Check the orientation of the front inner shift lever.

  25. REMOVE INNER NO. 1 SHIFT LEVER


    1. A01VIEP

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

      Tech Tips

      Check the orientation of the inner No. 1 shift lever.

  26. REMOVE INNER SELECT LEVER


    1. A01VDVQ

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

      Tech Tips

      Check the orientation of the inner select lever.

  27. REMOVE SHIFT AND SELECT LEVER SHAFT HEAD


    1. A01VLMV

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin and the shift and select lever shaft head from the shift and select lever shaft.

      Tech Tips

      Check the orientation of the shift and select lever shaft head.

  28. REMOVE SHIFT INTER LOCK PLATE


    1. A01VKM1

      Remove the shift inter lock plate from the front transaxle case.

  29. REMOVE INPUT SHAFT ASSEMBLY


    1. A01VE9W

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

  30. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01VI6B

      Remove the differential case assembly from the front transaxle case.

  31. 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. A01VGQ4E10
      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.

  32. 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.

  33. REMOVE TRANSMISSION MAGNET


    1. A01VF8W

      Remove the transmission magnet from the front transaxle case.

  34. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VK8U

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

  35. REMOVE BREATHER PLUG


    1. A01VIV7

      Remove the breather plug from the front transaxle case.

  36. 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.

  37. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01VE0HE02

      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 )

  38. REMOVE STRAIGHT PIN


    1. A01VG0Q

      Remove the 5 straight pins from the front transaxle case.

  39. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01VJD6

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

  40. REMOVE INPUT SHAFT COVER


    1. A01VF4G

      Remove the input shaft cover from the manual transmission case.

  41. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01VIBM

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

  42. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01VM83

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

  43. 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.

  44. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01VJBGE01

      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

  45. 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 )

  46. REMOVE TRANSMISSION CASE GASKET


    1. A01VJ53E01

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

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

  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 )