MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  3. REMOVE RELEASE FORK SUPPORT

    Click here

  4. REMOVE CLUTCH RELEASE FORK BOOT


    1. A004S8S

      Remove the clutch release fork boot from the front transaxle case.

  5. REMOVE CONTROL CABLE BRACKET


    1. A004QHJ

      Remove the 3 bolts and control cable bracket from the manual transaxle.

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A004T8F

      Remove the 2 bolts and selecting bell crank from the manual transmission case.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A004ODIE05

      Using SST, remove the back-up light switch and gasket.

      SST
      09816-30010

  8. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A004NGYE03

      Using SST, remove the park/neutral position switch and gasket.

      SST
      09816-30010

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A004PTY

      Remove the lock ball from the manual transmission case.

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A004OF6

      Remove the lock ball from the manual transmission case.

  11. REMOVE SHIFT GATE PIN


    1. A004SYH

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A004PUU

      Remove the 4 bolts and shift and select lever assembly from the manual transmission case.

  13. REMOVE SHIFT AND SELECT PIN


    1. A004P1G

      While pressing in the shift and select pin as far as it will go, pull out the shift and select pin to remove it.

    2. Remove the spring.

  14. REMOVE O-RING


    1. A004RFE

      Remove the O-ring from the shift and select pin.

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A004OGC

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

  16. REMOVE DRAIN PLUG


    1. A004OVH

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

  17. REMOVE BALL


    1. A004QB5

      Using a 6 mm hexagon wrench, remove the 4 detent ball plugs from the front transaxle case.

    2. Using a magnet hand, remove the 4 spring seats, 4 springs and 4 balls.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A004MW1

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A004TIU

      Remove the 2 manual transmission case plugs from the manual transmission case.

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A004R6R

      Remove the 6 bolts from the front transaxle case side.

    2. A004Q1H

      Remove the 12 bolts from the manual transmission case side.

    3. A004MUX

      Using 2 pairs of snap ring pliers to keep the snap ring stretched, remove the manual transmission case.

  21. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A004SL5

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

      Note

      Do not damage the No. 1 oil receiver pipe.

  22. REMOVE TRANSMISSION OIL SEPARATOR


    1. A004R1H

      for Manual Transmission Case Side:

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

  23. REMOVE 1ST AND 2ND SHIFT FORK SHAFT


    1. A004O99

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

    2. A004SPN

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A004TSF

      Using a 5 mm pin punch and hammer, tap out the pin from the No. 2 gear shift head.

    2. A004MXO

      Using a 5 mm pin punch and hammer, tap out the pin from the No. 2 gear shift fork.

    3. A004OAPE03
      Text in Illustration
      *1 3rd and 4th Shift Fork Shaft
      *2 No. 2 Gear Shift Head

      Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head.

  25. REMOVE NO. 2 GEAR SHIFT FORK


    1. A004RNW

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A004ML3

      Using a screwdriver, remove the E-ring from the front transaxle case.

    2. A004TAI

      Remove the pin from the front transaxle case.

    3. A004SV3

      Remove the No. 5 gear shift fork shaft from the front transaxle case.

    4. A004TDI

      Using a 5 mm pin punch and hammer, tap out the pin.

    5. Remove the No. 3 gear shift head.

  27. REMOVE NO. 1 GEAR SHIFT FORK


    1. A004U93

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

  28. REMOVE SHIFT ARM


    1. A004PQV

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A004R7V

      Remove the bolt from the reverse shift fork.

    2. A004NV3

      Remove the reverse shift fork shaft.

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A004R1C

      Remove the bolt from the No. 3 gear shift fork.

    2. A004O31

      Remove the 5th and 6th shift fork shaft.

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A004QBY

      Remove the No. 3 gear shift fork from the No. 2 output shaft assembly.

  32. REMOVE REVERSE SHIFT FORK


    1. A004Q2O

      Remove the reverse shift fork from the No. 2 output shaft assembly.

  33. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

    Click here

  34. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

    Click here

  35. REMOVE REVERSE IDLER GEAR


    1. A004QRK

      Remove the reverse idler gear shaft by sliding and lifting it.

    2. A004OQB

      Remove the reverse idler gear, needle roller bearing and reverse idler thrust washer from the reverse idler gear shaft.

  36. REMOVE INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT


    1. A004S93

      Remove the 3 shafts at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A004N9P

      for Front Transaxle Case Side:

      Remove the 2 bolts and transmission oil separator from the front transaxle case.

  38. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A004NTT

      Remove the differential case from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A004P4G

      Remove the transmission magnet from the front transaxle case.

  40. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE


    1. A004OCOE01

      Using SST, remove the No. 2 output shaft rear bearing outer race the manual transmission case to remove it.

      SST
      09387-00041   ( 09387-02020 )

  41. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A004SNW

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A004SIME04

      Using SST, remove the 4 shift fork shaft bearings from the manual transmission case to remove them.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )
      09527-20011

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A004O6LE01

      Using SST, remove the shift and select lever shaft needle roller bearing from the manual transmission case to remove it.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )

  44. REMOVE INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A004QKU

      Using snap ring expander, remove the 2 snap rings.

  45. REMOVE INPUT SHAFT FRONT BEARING


    1. A004MTH

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. A004PUME01

      Using SST, remove the input shaft bearing from the front transaxle case to remove it.

      SST
      09612-30012

  46. REMOVE TRANSAXLE CASE OIL SEAL


    1. A004SEG

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

  47. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A004TRP

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. A004S0KE04

      Using SST, remove the output shaft front bearing from the front transaxle case to remove it.

      SST
      09612-65014   ( 09612-01020 )

  48. REMOVE OUTPUT SHAFT COVER


    1. A004T5G

      Remove the output shaft cover from the front transaxle case.

  49. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE


    1. A004O56E01

      Using SST, remove the No. 2 output shaft front bearing outer race from the front transaxle case to remove it.

      SST
      09387-00041   ( 09387-02020 )

  50. REMOVE OUTPUT SHAFT COVER


    1. A004MX2

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING


    1. A004QNKE04

      Using SST, remove the 4 shift fork shaft bearings from the front transaxle case to remove them.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )

  52. REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. A004O22

      Using a screwdriver, remove the front drive shaft oil seal LH from the manual transmission case.

      Tech Tips

      Tape the screwdriver tip before use.

  53. REMOVE FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A004PQL

      Using a brass bar and hammer, tap out the front differential case rear outer race bearing and front differential case rear shim from the manual transmission case.

  54. REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. A004UEC

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

      Tech Tips

      Tape the screwdriver tip before use.

  55. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A004MWTE01

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

      SST
      09387-00041   ( 09387-02020 )