MULTI-MODE MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE SHIFT STROKE SENSOR

    A0138MQ

    1. Remove the 2 screws and the sensor from the shift and select actuator.

    2. Remove the O-ring from the sensor.

  2. REMOVE CLUTCH RELEASE FORK

    A0138HM

    1. Remove the clip from the release bearing.

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

    3. A0137AY

      Remove the E-ring from the fork lever.

    4. Remove the fork lever and fork.

  3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A0137EI

    1. Using a screwdriver, remove the oil seal.

  4. INSPECT NEUTRAL POSITION


    1. A0135SME01

      Remove the plug from the shift and select actuator.

    2. Look through the plug and check that the slit of the shift and select shaft is in the position shown in the illustration.

      If not, turn it with a screwdriver.

  5. REMOVE LOCK BALL ASSEMBLY NO.1


    1. A0135YJ

      Using an 18 mm socket wrench, remove the lock ball assembly from the transaxle case.

  6. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A0137KXE01

      Using SST, remove the park/neutral position switch with the gasket from the transaxle case.

      SST
      09817-16011

  7. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A0137SQ

      Remove the 6 bolts.

    2. Tap the actuator flange with a plastic hammer to remove it.

  8. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0136BAE01

      Using SST, remove the back-up light switch with the gasket from the transaxle case.

      SST
      09817-16011

  9. REMOVE TRANSMISSION REVOLUTION SENSOR


    1. A0137KP

      Remove the bolt and transmission case protector.

    2. Remove the bolt and transmission revolution sensor.

    3. Using a small screwdriver, remove the O-ring from the transmission revolution sensor.

  10. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A0136H0

      Remove the reverse idler gear shaft lock bolt with the gasket from the transmission case.

  11. REMOVE MANUAL TRANSMISSION CASE


    1. A01367G

      Remove the 13 bolts.

    2. Using a brass bar and hammer, tap the projection of the transmission case and remove the case.

    3. A0138W3

      Remove the shim from the transmission case.

  12. REMOVE SHIFT HEAD SET SLOTTED SPRING PIN


    1. A0138ZE

      Using a pin punch and hammer, drive out the 2 slotted spring pins out of gear shift heads No. 1 and No. 3.

  13. REMOVE GEAR SHIFT FORK SHAFT NO.1


    1. A0138AG

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

    2. Pull out gear shift fork shaft No.1 and the snap ring from the transaxle case.

    3. Remove gear shift head No.1 and gear shift fork No. 1.

    4. A0137DC

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

  14. REMOVE GEAR SHIFT FORK SHAFT NO.3

    A0137WE

    1. Using a magnetic finger, remove the straight pin from gear shift fork No. 3.

    2. A01375J

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

    3. A0137JN

      Cover gear shift fork shaft No.3 with a piece of cloth gear shift fork shaft No. 3 at the upper edge with pliers as shown in the illustration, and pull gear shift fork shaft No. 3 out of the transaxle case to remove gear shift fork No. 3, compression spring and gear shift head No. 3.

  15. REMOVE REVERSE IDLER GEAR SHAFT


    1. A013939

      Remove the reverse idler gear shaft from the transaxle case.

  16. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A0138OH

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

  17. REMOVE GEAR SHIFT FORK SHAFT NO.2


    1. A0137D0

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

    2. A0137U5

      Shift hub sleeve No. 2 into the 3rd gear, as shown.

    3. A0137KD

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

    4. Pull out gear shift fork snap rings, gear shift fork and the reverse shift fork from the transaxle case.

    5. A0135WR

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

    6. Remove the reverse shift fork from gear shift fork shaft No. 2.

    7. A0137VZ

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

    8. Remove gear shift fork No. 2 from gear shift fork shaft No. 2.

  18. REMOVE INPUT SHAFT


    1. A0138L1E01

      Remove the input shaft assembly from the manual transaxle case.

  19. REMOVE OUTPUT SHAFT


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

  20. REMOVE FRONT DIFFERENTIAL CASE


    1. A0138QQE01

      Remove the differential case assembly from the front transaxle case.

  21. REMOVE OIL RECEIVER PIPE NO.2(MTM)


    1. A0138KTE02

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

      Note

      Do not damage oil receiver pipe No. 2.

  22. REMOVE TRANSMISSION MAGNET


    1. A0138HOE01

      Remove the transmission magnet from the front transaxle case.

  23. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A013616E01

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

  24. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A0138KPE02

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

      SST
      09308-00010

  25. REMOVE OUTPUT SHAFT(MTM) COVER


    1. A0138WOE01

      Remove the output shaft (MTM) cover from the front transaxle case.

  26. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01371ZE01

      Using a screwdriver, remove the transmission case oil seal.

  27. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A0137BFE02

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

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

  28. REMOVE TRANSAXLE CASE OIL SEAL


    1. A0137WKE01

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

  29. REMOVE FR0NT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0135U3E02

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

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

  30. REMOVE INPUT SHAFT REAR BEARING SHIM


    1. A013857E01

      Remove the input shaft rear bearing shim.

  31. REMOVE OUTPUT SHAFT REAR BEARING


    1. A0137SJE02

      Using SST, remove the output shaft rear bearing.

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

  32. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A0137B0E01

      Remove the output shaft rear bearing shim.