MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. B0040IX

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. B0040GM

      Using a 10 mm hexagon socket wrench, remove the manual transmission drain plug and gasket from the front transaxle case.

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. B0040L7

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B0040N8

      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. B0040MX

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

  6. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0040GZ

      Remove the bolt and wire harness clamp bracket from the manual transmission case.

  7. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. B0040FI

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

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  10. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  11. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  12. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. B0040O7

      Place the manual transaxle assembly on wooden blocks.

  13. REMOVE TRANSMISSION CASE PLUG


    1. B0040HO

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

  14. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. B0040OK

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

  15. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. B0040GN

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

  16. REMOVE LOCK BALL PIN


    1. B0040O2

      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.

  17. REMOVE SHIFT DETENT BALL


    1. B0040M2

      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. B0040L4

      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.

  18. REMOVE OUTER SHIFT LEVER E RING


    1. B0040HF

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. B0040MT

      Remove the 16 bolts.

    2. B0040HME01
      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. B0040Q1E01
      Text in Illustration
      *1 Boss

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

    4. B0040Q5

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

  20. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. B0040GG

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

  21. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. B0040H0

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

  22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. B0040JG

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

  23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. B0040M8

      Using a 6 mm hexagon socket wrench, remove the inner select lever set bolt.

    2. B0040FB

      Turn the shift and select lever shaft assembly and shift inter lock plate clockwise and remove them from the front transaxle case.

  24. REMOVE OUTER SELECT LEVER


    1. B0040PR

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

  25. REMOVE OUTER SELECT LEVER OIL SEAL


    1. B0040OTE01
      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.

  26. REMOVE INPUT SHAFT ASSEMBLY


    1. B0040HJ

      Remove the input shaft assembly, output shaft assembly and 3 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 and No. 3 gear shift fork shaft assemblies from the input shaft assembly.

  27. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. B0040K3

      Remove the differential case assembly from the front transaxle case.

  28. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. B0040F1E01

      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. B0040GAE04
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the front differential case 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   ( 09951-00390 )

  29. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. B0040G4E05

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

      SST
      09308-00010
    2. B0040FQE02
      Text in Illustration
      *1 Turn
      *2 Hold

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00390 )

  30. REMOVE TRANSMISSION MAGNET


    1. B0040FT

      Remove the transmission magnet from the front transaxle case.

  31. REMOVE TRANSMISSION OIL SEPARATOR


    1. B0040HC

      For front transaxle case side:

      Remove the 4 bolts and transmission oil separator from the front transaxle case.

  32. REMOVE BREATHER PLUG


    1. B0040NJ

      Remove the breather plug from the front transaxle case.

  33. REMOVE FRONT OUTPUT SHAFT BEARING


    1. B0040O6E01

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

      SST
      09308-00010
    2. B0040P7

      Remove the output shaft cover from the front transaxle case.

  34. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. B0040LKE01

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

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

  35. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. B0040QB

      Remove the reverse restrict pin assembly from the front transaxle case.

  36. REMOVE STRAIGHT PIN


    1. B0040IS

      Remove the 5 straight pins from the front transaxle case.

  37. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. B0040JL

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

  38. REMOVE INPUT SHAFT COVER


    1. B0040MI

      Remove the input shaft cover from the manual transmission case.

  39. REMOVE NO. 1 OIL RECEIVER PIPE


    1. B0040NN

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

  40. REMOVE TRANSMISSION OIL SEPARATOR


    1. B0040Q2

      For manual transmission case side:

      Remove the 2 bolts and transmission oil separator from the manual transmission case.

  41. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. B0040M5

      Remove the 4 bolts and manual transmission oil separator sub-assembly from the manual transmission case.

  42. REMOVE OUTER NO. 1 SHIFT LEVER


    1. B0040JY

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

      Tech Tips

      When removing the slotted spring pin, align the pin with the hole in the No. 1 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.

  43. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. B0040FEE02
      Text in Illustration
      *1 Protective Tape

      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.

  44. REMOVE REAR OUTPUT SHAFT BEARING


    1. B0040PPE07

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

      SST
      09308-00010

  45. REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. B0040QOE01

      1. Using SST, remove the front drive shaft oil seal LH from the manual transmission case.

        SST
        09950-60010   ( 09951-00620 )
        09950-70010   ( 09951-07150 )

  46. REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. B0040F4E01

      1. Using SST, remove the front drive shaft oil seal RH from the front transaxle case.

        SST
        09950-60010   ( 09951-00530 )
        09950-70010   ( 09951-07150 )