MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A0057V2

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A00570W

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

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0055H7

      Using a 27 mm deep socket wrench, remove the back-up light switch and gasket from the manual transmission case.

  4. REMOVE NEUTRAL POSITION SWITCH


    1. A00551J

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

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A0057KB

      Remove the 3 bolts and control cable bracket from the manual transmission case.

  6. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  8. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  9. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  10. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  11. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A0055ZG

      Place the manual transaxle on wooden blocks.

  12. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A005697

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

  13. REMOVE LOCK BALL PIN


    1. A0055UV

      Using a 10 mm hexagon socket wrench, remove the plug from the manual transmission case.

    2. Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.

    3. A0056JK

      Using a 10 mm hexagon socket wrench, remove the plug from the manual transmission case.

    4. Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.

  14. REMOVE SHIFT DETENT BALL


    1. A00546S

      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 compression spring and shift detent ball from the manual transmission case.

    3. A0055LH

      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 compression springs and 2 shift detent balls from the manual transmission case.

  15. REMOVE OUTER SHIFT LEVER E-RING


    1. A0053NY

      Remove the E-ring from the outer No. 1 shift lever.

  16. REMOVE MANUAL TRANSMISSION CASE


    1. A0056NY

      Remove the 17 bolts.

    2. A0058DRE01
      Text in Illustration
      *1 Protective Tape

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

      Note

      Do not damage the manual transmission case.

    3. A0053AL

      Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.

    4. A005970

      Push the outer No. 1 shift lever and remove the manual transmission case.

  17. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A0057YM

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

  18. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A0053I6

      Turn the reverse shift fork shaft clockwise and remove it from the front transaxle case.

  19. REMOVE REVERSE SHIFT FORK


    1. A0054WX

      Using a 5 mm pin punch and hammer, tap out the reverse shift fork slotted spring pin.

    2. Remove the reverse shift fork from the reverse shift fork shaft.

  20. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A0057RN

      Using a 6 mm hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket from the front transaxle case.

  21. REMOVE OUTER SELECT LEVER


    1. A0055JN

      Remove the inner select lever bolt.

    2. A005508

      Remove the outer select lever and inner select lever from the front transaxle case.

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A0054NY

      Turn the shift and select lever shaft clockwise and remove it from the front transaxle case.

  23. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A0054LIE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the front transaxle case.

      Note

      Do not damage the installation surfaces.

  24. REMOVE INPUT SHAFT ASSEMBLY


    1. A0059J1

      Remove the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.

    2. Remove the output shaft assembly together with the No. 1 gear shift fork shaft assembly from the input shaft assembly.

    3. Remove the No. 1 gear shift fork shaft assembly from the output shaft assembly.

    4. Remove the No. 2 gear shift fork shaft assemblies from the input shaft assembly.

  25. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A0052S7

      Remove the differential case from the front transaxle case.

  26. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0055HTE04

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

      SST
      09308-00010
    2. A00596ZE01
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the differential case assembly 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   ( 09951-00350, 09951-00550, 09952-06010 )

  27. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00578GE01

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

      SST
      09308-00010
    2. A0057B4E01
      Text in Illustration
      *1 Turn
      *2 Hold

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00350, 09951-00550, 09952-06010 )

  28. REMOVE TRANSMISSION MAGNET


    1. A0058R0

      Remove the transmission magnet from the front transaxle case.

  29. REMOVE BREATHER PLUG


    1. A0056PI

      Remove the breather plug from the front transaxle case.

  30. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A00573WE01

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

      SST
      09308-00010
    2. A0052FY

      Remove the output shaft cover from the front transaxle case.

  31. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A0056ZGE01

      Using SST, tap out the front transaxle case oil seal from the front transaxle case.

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07150 )

  32. REMOVE STRAIGHT PIN


    1. A0058MJ

      Remove the 5 straight pins from the front transaxle case.

  33. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A0058PA

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

  34. REMOVE INPUT SHAFT COVER


    1. A005493

      Remove the input shaft cover from the manual transmission case.

  35. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A0058XM

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

  36. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A005659

      Using a 5 mm pin punch and hammer, tap out the inner shift lever slotted spring pin.

      Tech Tips

      When removing the slotted spring pin, align the pin with the hole in the lock ball assembly.

    2. Remove the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever from the manual transmission case.

  37. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A0054LI

      Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the front transaxle case.

      Note

      Do not damage the installation surfaces.

  38. REMOVE REAR OUTPUT SHAFT BEARING


    1. A00588BE01

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

      SST
      09308-00010

  39. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

    Click here

  40. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

    Click here