MANUAL TRANSAXLE UNIT DISASSEMBLY

REMOVE RELEASE FORK RETRACTING SPRING HANGER
1. Remove the bolt and the release fork retracting spring hanger.
REMOVE CLUTCH RELEASE BEARING ASSEMBLY
1. Remove the clutch release bearing from the clutch release fork.
REMOVE CLUTCH RELEASE FORK LEVER
1. Separate the torsion spring from the clutch release fork.
2. Using 2 screwdrivers and a hammer, tap the E-ring out.
3. 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.
REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL
1. Using a screwdriver, remove the clutch release fork lever oil seal.
REMOVE NO. 1 CLUTCH HOUSING COVER
1. Remove the No. 1 clutch housing cover from the transaxle case.
REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Remove the 2 bolts and cable control bracket from the transaxle case.
REMOVE MANUAL TRANSAXLE CASE PLUG
1. Remove the manual transaxle case plug and gasket from the transaxle case.
REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Separate the back-up light switch wire harness from the 2 clamps.
2. Using SST, remove the back-up light switch and gasket from the transmission case.
  
  SST
  
  09817-16011
REMOVE NO. 1 LOCK BALL ASSEMBLY
1. Remove the No. 1 lock ball assembly from the transmission case.
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
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.
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and gasket.
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 5 bolts from the transaxle case side.
2. Remove the 8 bolts from the transmission case side.
3. Using a plastic hammer, remove the transmission case.
REMOVE REVERSE IDLER GEAR SHAFT
1. Remove the reverse idler gear shaft from the transaxle case.
REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
1. Remove the reverse idler gear from the transaxle case.
REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and the reverse shift arm bracket from the transaxle case.
REMOVE NO. 1 GEAR SHIFT FORK SHAFT
1. Remove the bolt from the No. 1 gear shift fork.
2. Using a pin punch and hammer, remove the slotted spring pin from the No. 1 gear shift head.
3. Remove the No. 1 gear shift fork shaft, No. 1 gear shift head and No. 1 gear shift fork.
4. 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.
REMOVE NO. 3 GEAR SHIFT FORK SHAFT
1. Remove the straight pin from the No. 3 gear shift fork.
2. Using a pin punch and hammer, remove the slotted spring pin from the No. 3 gear shift head.
3. 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. Remove the No. 3 gear shift fork shaft, compression spring, No. 3 gear shift head and No. 3 gear shift fork from the transaxle case.
5. 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.
REMOVE NO. 2 GEAR SHIFT FORK SHAFT
1. Using a magnet hand, remove the straight pin from the reverse shift fork.
2. 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. Remove the bolt from the No. 2 gear shift fork.
4. Shift the No. 2 gear shift fork to the 4th gear range.
5. Remove the No. 2 gear shift fork shaft, No. 2 gear shift fork and reverse shift fork.
6. 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.
REMOVE INPUT SHAFT ASSEMBLY
1. Remove the input shaft assembly from the transaxle case.
REMOVE OUTPUT SHAFT ASSEMBLY
1. Remove the output shaft assembly from the transaxle case.
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Remove the differential case assembly from the transaxle case.
REMOVE NO. 2 OIL RECEIVER PIPE
1. Remove the No. 2 oil receiver pipe from the transmission case.
  
  Note
  
  Do not damage the No. 2 oil receiver pipe.
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the transaxle case.
REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal.
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing (outer race) from the transaxle case.
  
  SST
  
  09308-00010
REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the transaxle case.
REMOVE TRANSMISSION CASE OIL SEAL
1. Using a screwdriver, remove the transmission case oil seal.
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing and the shim.
  
  SST
  
  09950-60010 ( 09951-00560 )
  
  09950-70010 ( 09951-07200 )
REMOVE TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the transaxle case oil seal from the transaxle case.
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing.
  
  SST
  
  09387-00041 ( 09387-02010, 09387-02020 )
REMOVE INPUT SHAFT REAR BEARING SHIM
1. Remove the input shaft rear bearing shim from the transmission case.
REMOVE OUTPUT SHAFT REAR BEARING
1. Using SST, remove the output shaft rear bearing.
  
  SST
  
  09527-30010
  
  09612-65014 ( 09612-01030, 09612-01050 )
REMOVE OUTPUT SHAFT REAR BEARING SHIM
1. Remove the output shaft rear bearing shim.