MANUAL TRANSAXLE ASSEMBLY 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 off.

    3. A01389B

      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


    1. A01375E

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

  5. REMOVE CLUTCH HOUSING COVER NO.1

    A013662

    1. Remove the clutch housing cover from the transaxle case.

  6. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET

    A01365I

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

  7. REMOVE MANUAL TRANSAXLE CASE PLUG

    A0136MB

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

  8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    A0138Y0E01

    1. Separate the back-up light switch wire harness from the clamp bracket.

      Tech Tips


      • For bend type :

        Expand the clamp with your finger and separate the harness from the bracket.

      • For clamp type :

        Pull the wire harness out and separate it from the bracket.

    2. A0138RE

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

      SST
      09817-16011

  9. REMOVE LOCK BALL ASSEMBLY NO. 1

    A0136BH

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

  10. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    A0136GU

    1. Remove the 4 bolts and shift and select lever shaft from the transmission case.

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

  11. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    A0136JQ

    1. Remove the reverse idler gear shaft bolt and gasket.

  12. REMOVE MANUAL TRANSMISSION CASE

    A01361H

    1. Remove the 5 bolts from the manual transaxle case side.

    2. A01382OE01

      Remove the 8 bolts from the manual transmission case side.

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

  13. REMOVE REVERSE IDLER GEAR SHAFT

    A013834

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

  14. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. Remove the reverse idler gear from the transaxle case.

  15. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    A01378G

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

  16. REMOVE GEAR SHIFT FORK SHAFT NO. 1

    A0138EB

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

    2. A0136O9

      Using a pin punch and hammer, remove the slotted spring pin from gear shift head No. 1.

    3. A0136BU

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

    4. A013603

      Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork shaft No. 1.

  17. REMOVE GEAR SHIFT FORK SHAFT NO. 3

    A01365U

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

    2. A0136BK

      Using a pin punch and hammer, remove the slotted spring pin from gear shift head No. 3.

    3. A0136XZ

      Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork shaft No. 3.

      Tech Tips

      Use a shop rag or piece of cloth to prevent the snap ring from flying off.

    4. A0136GP

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

    5. A0137PZ

      Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork shaft No. 3.

      Tech Tips

      Use a shop rag or piece of cloth to prevent the snap ring from flying off.

  18. REMOVE GEAR SHIFT FORK SHAFT NO. 2

    A0138MOE01

    1. Using a magnetic finger, remove the straight pin from the reverse shift fork.

    2. A0136EW

      Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork shaft No. 3.

      Tech Tips

      Use a shop rag or piece of cloth to prevent the snap ring from flying off.

    3. A0136DA

      Remove the bolt from gear shift fork No. 2.

    4. A0136B7

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

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

    6. A0136RG

      Using 2 screwdrivers and a hammer, remove the snap ring from gear shift fork shaft No. 2.

      Tech Tips

      Use a shop rag or piece of cloth to prevent the snap ring from flying off.

  19. REMOVE INPUT SHAFT ASSEMBLY

    A0138L1

    1. Remove the input shaft assembly from the manual transaxle case.

  20. REMOVE OUTPUT SHAFT ASSEMBLY


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

  21. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A0138QQ

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

  22. REMOVE OIL RECEIVER PIPE NO. 2

    A0138KTE01

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

      Note

      Do not damage oil receiver pipe No. 2.

  23. REMOVE TRANSMISSION MAGNET

    A0138HO

    1. Remove the transmission magnet from the front transaxle case.

  24. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    A013616

    1. Using a screwdriver, remove the front transaxle case oil seal.

  25. REMOVE OUTPUT SHAFT FRONT BEARING

    A0138KPE01

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

      SST
      09308-00010

  26. REMOVE OUTPUT SHAFT COVER

    A0138WO

    1. Remove the output shaft cover from the transaxle case.

  27. REMOVE TRANSMISSION CASE OIL SEAL

    A01371Z

    1. Using a screwdriver, remove the transmission case oil seal.

  28. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    A0137BFE01

    1. Using SST, remove the front differential case rear tapered roller bearing and the shim.

      SST
      09950-60010   ( 09951-00560 )
      09950-70010   ( 09951-07200 )

  29. REMOVE TRANSAXLE CASE OIL SEAL

    A0137WK

    1. Using a screwdriver, remove the transaxle case oil seal from the transaxle case.

  30. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A0135U3E01

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

      SST
      09387-00041   ( 09387-02010, 09387-02020 )

  31. REMOVE INPUT SHAFT REAR BEARING SHIM

    A013857

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

  32. REMOVE OUTPUT SHAFT REAR BEARING

    A0137SJE01

    1. Using SST, remove the output shaft rear bearing.

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

  33. REMOVE OUTPUT SHAFT REAR BEARING SHIM

    A0137B0

    1. Remove the output shaft rear bearing shim.

  34. INSPECT 3RD GEAR THRUST CLEARANCE

    A0137WV

    1. Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

  35. INSPECT 5TH GEAR THRUST CLEARANCE

    A0137MU

    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.50 mm (0.0039 to 0.0197 in.)
      Maximum clearance
      0.50 mm (0.0197 in.)

  36. INSPECT 3RD GEAR RADIAL CLEARANCE

    A0138MV

    1. Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing or the shaft.

  37. INSPECT 4TH GEAR RADIAL CLEARANCE

    A0137SE

    1. Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 4th gear needle roller bearing or the shaft.

  38. INSPECT 5TH GEAR RADIAL CLEARANCE

    A0137C1

    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 5th gear needle roller bearing or the shaft.

  39. REMOVE 5TH GEAR

    A0137DYE02

    1. Using SST and a press, remove the input shaft rear radial ball bearing, hub sleeve No. 3, 5th gear synchronizer ring and 5th gear from the input shaft.

      SST
      09950-00020
      09612-24014   ( 09612-10061 )

      Tech Tips


      • Support the input shaft by hand to prevent it from dropping off.

      • Set the claw of SST between the 4th gear and 5th gear, as shown in the illustration.

      Note

      Do not excessively tighten SST.

  40. REMOVE TRANSMISSION CLUTCH HUB NO. 3

    A0135VR

    1. Remove the 2 No. 3 shifting key springs from transmission clutch hub No. 3.

    2. Remove transmission hub sleeve No. 3 from transmission clutch hub No. 3.

    3. Remove the 3 No.3 shifting keys from transmission clutch hub No. 3.

  41. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

    A0136ZC

    1. Remove the 5th gear needle roller bearing from the input shaft.

  42. REMOVE 5TH GEAR BEARING SPACER

    A0138A1

    1. Remove the 5th gear bearing spacer from the input shaft.

  43. INSPECT 4TH GEAR THRUST CLEARANCE

    A0138IV

    1. Using a dial indicator, measure the 4th gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217 in.)

  44. REMOVE 5TH GEAR SHAFT SNAP RING

    A0136AK

    1. Using a snap ring expander, remove the 5th gear shaft snap ring from the input shaft.

      Tech Tips

      Do not damage the journal surface of the input shaft.

  45. REMOVE 5TH GEAR THRUST WASHER

    A0136F5

    1. Remove the 5th gear thrust washer from the input shaft.

  46. REMOVE 5TH GEAR THRUST WASHER BALL

    A01365W

    1. Using a magnetic finger, remove the ball from the input shaft.

  47. REMOVE 4TH GEAR

    A0138HK

    1. Remove the 4th gear from the input shaft.

  48. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

    A0136PL

    1. Remove the 4th gear needle roller bearing from the input shaft.

  49. REMOVE 4TH GEAR BEARING SPACER

    A0137ZY

    1. Remove the 4th gear bearing spacer from the input shaft.

  50. REMOVE 4TH GEAR SYNCHRONIZER RING

    A0137LX

    1. Remove the 4th gear synchronizer ring from clutch hub No. 2.

  51. REMOVE CLUTCH HUB NO. 2 SETTING SHAFT SNAP RING

    A01369C

    1. Using a snap ring expander, remove clutch hub No. 2 setting shaft snap ring from the input shaft.

      Tech Tips

      Do not damage the journal surface of the input shaft.

  52. REMOVE 3RD GEAR

    A0138WKE02

    1. Using SST and a press, remove the hub sleeve No. 2, 3rd gear synchronizer ring and 3rd gear from the input shaft.

      SST
      09950-00020

      Note

      Do not excessively tighten SST.

      Tech Tips

      Support the input shaft by hand to prevent it from dropping off.

  53. REMOVE TRANSMISSION CLUTCH HUB NO. 2

    A0136P7

    1. Remove the 2 No. 2 shifting key springs from transmission clutch hub No. 2.

    2. Remove transmission hub sleeve No. 2 from transmission clutch hub No. 2.

    3. Remove the 3 No. 2 shifting keys from transmission clutch hub No. 2.

  54. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    A01360C

    1. Remove the 3rd gear needle roller bearing from the input shaft.

  55. REMOVE INPUT SHAFT FRONT BEARING

    A01361ME03

    1. Using a press, remove the input shaft front bearing from the input shaft.

      SST
      09950-00020

      Tech Tips

      Support the input shaft by hand to prevent it from dropping off.

  56. REMOVE OUTPUT SHAFT REAR BEARING

    A0136W2E02

    1. Using SST and a press, remove the output shaft rear bearing.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )

  57. INSPECT 1ST GEAR THRUST CLEARANCE

    A0137ZK

    1. Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138)

  58. INSPECT 2ND GEAR THRUST CLEARANCE

    A0138I1

    1. Using a feeler gauge, measure the 2nd gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217)

  59. INSPECT 1ST GEAR RADIAL CLEARANCE

    A0138AJ

    1. Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 in.)

      If the clearance exceeds the maximum, replace the 1st gear, needle roller bearing or shaft.

  60. INSPECT 2ND GEAR RADIAL CLEARANCE

    A0138TQ

    1. Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 in.)

      If the clearance exceeds the maximum, replace the 2nd gear, needle roller bearing or shaft.

  61. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING

    A0136BZ

    1. Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ring from the output shaft.

  62. REMOVE 4TH DRIVEN GEAR

    A0138U8

    1. Using a press, remove the 5th driven gear with the 4th driven gear from the output shaft.

  63. REMOVE OUTPUT SHAFT SPACER

    A01369A

    1. Remove the output shaft spacer from the output shaft.

  64. REMOVE 2ND GEAR

    A01380EE02

    1. Using SST and a press, remove the 3rd driven gear with the 2nd gear from the output shaft.

      SST
      09950-00020

  65. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

    A0136T6

    1. Remove the 2nd gear needle roller bearing from the output shaft.

  66. REMOVE 2ND GEAR BEARING SPACER

    A0136R0

    1. Remove the 2nd gear bearing spacer from the output shaft.

  67. REMOVE 2ND GEAR SYNCHRONIZER RING

    A0137ES

    1. Remove the 2nd gear synchronizer ring from the reverse gear.

  68. REMOVE CLUTCH HUB NO. 1 SHAFT SNAP RING

    A0137OO

    1. Using a snap ring expander, remove the clutch hub No. 1 shaft snap ring from the output shaft.

      Tech Tips

      Do not damage the journal surface of the output shaft.

  69. REMOVE 1ST GEAR

    A01361F

    1. Using a press, remove transmission clutch hub No. 1 and the 1st gear from the output shaft.

  70. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    A0138NB

    1. Remove the 1st gear needle roller bearing from the output shaft.

  71. REMOVE OUTPUT SHAFT FRONT BEARING

    A01374YE02

    1. Using SST and a press, remove the output shaft front bearing from the output shaft.

      SST
      09950-00020

  72. REMOVE TRANSMISSION CLUTCH HUB NO. 1

    A0135TT

    1. Remove the 2 No. 1 shifting key springs, 3 No. 1 shifting keys and reverse gear from transmission clutch hub No. 1.

  73. REMOVE SHIFT LEVER INNER NO. 1

    A013874

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

      Tech Tips

      Check the orientation of shift lever inner No. 1 before removing it.

    2. A0136FV

      Using 2 screwdrivers and a hammer, remove the snap ring from the shift and select lever shaft.

    3. A0136B2

      Remove shift lever inner No .1 and the shift interlock plate from the shift and select lever shaft.

  74. REMOVE SELECT RETURN COMPRESSION SPRING

    A0137I3

    1. Remove the select return compression spring from the shift and select lever shaft.

  75. REMOVE SELECT SPRING SEAT NO. 2

    A0137NK

    1. Remove select spring seat No. 2 from the shift and select lever shaft.

  76. REMOVE SELECT LEVER SHAFT

    A0136IM

    1. Remove the bolt.

    2. Remove the select lever shaft from the control shaft cover.

  77. REMOVE SELECT INNER LEVER

    A0137C5

    1. Remove the select inner lever from the control shaft cover.

  78. REMOVE SHIFT AND SELECT LEVER SHAFT

    A0136GIE01

    1. Using 2 screwdrivers and a hammer, remove the snap ring from the shift and select lever shaft.

      Tech Tips

      Lift the control shaft cover up with a piece of rope or equivalent to make the work easier.

    2. A0137E4

      Remove the shift and select lever shaft with the shift lever boot from the control shaft cover.

    3. Remove the shift lever boot from the shift and select lever shaft.

    4. A0138AZ

      Using a small screwdriver, remove the spacer from the shift and select lever shaft.

  79. REMOVE SELECT LEVER SHAFT OIL SEAL

    A01382P

    1. Using a screwdriver, remove the select lever shaft oil seal from the control shaft cover.

  80. REMOVE CONTROL SHAFT COVER OIL SEAL

    A0138R7

    1. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.

  81. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A0136ES

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

      SST
      09950-00020
      09950-00030

      Tech Tips

      Set the claw of SST to the bearing inner race at the indented part of the differential case.

  82. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    A0137MDE03

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

      SST
      09950-00020
      09950-00030

  83. REMOVE FRONT DIFFERENTIAL RING GEAR

    A0136BXE03

    1. Place matchmarks on the front differential ring gear and the front differential case.

    2. Remove the 6 bolts.

    3. A01392Y

      Using a hammer, remove the front differential ring gear from the front differential case.

  84. REMOVE FRONT DIFFERENTIAL CASE

    A0137O1

    1. Using a pin punch and hammer, remove the pinion shaft slotted spring pin.

    2. A0136LE

      Remove the pinion shaft from the differential case.

    3. Remove the 2 pinion gears, 2 side gears and the 4 thrust washers from each gear.