MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE RELEASE FORK RETRACTING SPRING HANGER

    A01367T

    1. Remove the bolt and the release fork retracting spring hanger.

  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    A0138DD

    1. Remove the clutch release bearing from the clutch release fork.

  3. REMOVE CLUTCH RELEASE FORK LEVER

    A0135ZF

    1. Separate the torsion spring from the clutch release fork.

    2. A013743

      Using 2 screwdrivers and a hammer, tap the E-ring out.

    3. A01379J

      Pull the clutch release fork lever out of the transaxle case to remove the clutch release fork and then, release the fork torsion spring stopper and torsion spring from the clutch.

  4. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A01375E

    1. Using a screwdriver, remove the clutch release fork lever oil seal.

  5. REMOVE NO. 1 CLUTCH HOUSING COVER

    A013662

    1. Remove the No. 1 clutch housing cover from the transaxle case.

  6. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A01365I

      Remove the 2 bolts and cable control bracket from the front transaxle case.

  7. REMOVE MANUAL TRANSAXLE CASE PLUG


    1. A0136MB

      Remove the manual transaxle case plug and gasket from the front transaxle case.

  8. REMOVE MANUAL TRANSAXLE DRAIN PLUG


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

  9. REMOVE MANUAL TRANSAXLE FILLER PLUG


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

  10. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01379K

      Separate the back-up light switch wire harness from the 2 clamps.

    2. A0138REE01

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

      SST
      09817-16011

  11. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A0136U5

      Remove the No. 1 lock ball assembly from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A0136GU

      Remove the 4 bolts, 2 clamps and the shift and select lever shaft assembly from the manual transmission case.

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

  13. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A0136JQ

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

  14. REMOVE MANUAL TRANSMISSION CASE


    1. A0137FO

      Remove the 5 bolts from the front transaxle case side.

    2. A0137UP

      Remove the 8 bolts from the manual transmission case side.

    3. Using a plastic hammer, remove the manual transmission case.

  15. REMOVE REVERSE IDLER GEAR SHAFT


    1. A013834E01

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

  16. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


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

  17. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01378GE01

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

  18. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A0138EBE01

      Remove the bolt from the No. 1 gear shift fork.

    2. A0136O9E01

      Using a pin punch 5 mm and a hammer, tap out the slotted spring pin from the No. 1 gear shift head.

    3. A0136BUE01

      Remove the No. 1 gear shift fork shaft, No. 1 gear shift head and the No. 1 gear shift fork.

    4. A013603E01

      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.

  19. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A01365UE01

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

    2. A0136BKE01

      Using a pin punch 5 mm and a hammer, tap out the slotted spring pin from the No. 3 gear shift head.

    3. A0136XZE01

      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. A0136GPE01

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

    5. A0137PZE01

      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.

  20. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A0138MOE02

      Using a magnet hand, remove the straight pin from the reverse shift fork.

    2. A0136EWE01

      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. A0136DAE01

      Remove the bolt from the No. 2 gear shift fork.

    4. A0136B7E01

      Shift the No. 2 gear shift fork to the 4th gear position.

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

    6. A0136RGE01

      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.

  21. REMOVE INPUT SHAFT ASSEMBLY


    1. A0138L1E01

      Remove the input shaft assembly from the front transaxle case.

  22. REMOVE OUTPUT SHAFT ASSEMBLY


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

  23. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A0138QQE01

      Remove the differential case assembly from the front transaxle case.

  24. REMOVE NO. 2 OIL RECEIVER PIPE


    1. A0136GW

      Remove the No. 2 oil receiver pipe from the manual transmission case.

  25. REMOVE TRANSMISSION MAGNET


    1. A0138HOE01

      Remove the transmission magnet from the front transaxle case.

  26. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A013616E01

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

      Note

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

  27. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A0138KPE01

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

      SST
      09308-00010

  28. REMOVE OUTPUT SHAFT COVER


    1. A0138WOE01

      Remove the output shaft cover from the front transaxle case.

  29. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01364QE01

      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.

  30. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A0137BFE01

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

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07200 )

  31. REMOVE TRANSAXLE CASE OIL SEAL


    1. A0136VGE01

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

      SST
      09308-00010

      Note

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

  32. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0138VEE01

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

      SST
      09308-00010

  33. REMOVE INPUT SHAFT REAR BEARING SHIM


    1. A013857E01

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

  34. REMOVE OUTPUT SHAFT REAR BEARING


    1. A0137SJE01

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

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

  35. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A0137B0E01

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