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

    Click here

  5. REMOVE CONTROL CABLE BRACKET


    1. A002NRS

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

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A002NRU

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  8. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A002N7A

      Remove the lock ball from the manual transmission case.

  9. REMOVE NEUTRAL POSITION SWITCH (w/ Stop And Start System)

    Click here

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A002Q6T

      Remove the lock ball from the manual transmission case.

  11. REMOVE SHIFT GATE PIN


    1. A002LY2

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A002QMN

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

  13. REMOVE SHIFT AND SELECT PIN


    1. A002QOD

      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. A002MFR

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A002NP5

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

  16. REMOVE DRAIN PLUG


    1. A002Q9A

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

  17. REMOVE BALL


    1. A002PB1

      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. A002NIJ

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A002MGS

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A002N4Z

      Remove the 6 bolts from the front transaxle case side.

    2. A002OJC

      Remove the 12 bolts from the manual transmission case side.

    3. A002N1Z

      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. A002OB0

      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. A002QWO

      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. A002OWV

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

    2. A002P64

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A002OKI

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

    2. A002Q4G

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

    3. A002M5GE03
      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. A002Q4U

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A002QY5

      Using a screwdriver, remove the E-ring from the pin.

    2. A002QRX

      Remove the pin from the shift arm.

    3. A002QJK

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

    4. A002PGJ

      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. A002OIH

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

  28. REMOVE SHIFT ARM


    1. A002LI5

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A002PZ3

      Remove the bolt from the reverse shift fork.

    2. A002NQH

      Remove the reverse shift fork shaft.

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A002MF5

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

    2. A002M53

      Remove the 5th and 6th shift fork shaft.

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A002O9N

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

  32. REMOVE REVERSE SHIFT FORK


    1. A002N33

      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. A002P7R

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

    2. A002MHB

      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. A002PQJ

      Remove the 3 shafts at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A002P59

      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. A002MT1

      Remove the differential case from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A002M6P

      Remove the transmission magnet from the front transaxle case.

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


    1. A002LZPE01

      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. A002OKN

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A002PLOE03

      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. A002MDIE01

      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. A002MAJ

      Using snap ring expander, remove the 2 snap rings.

  45. REMOVE INPUT SHAFT FRONT BEARING


    1. A002NGN

      Remove the bolt from the front transaxle case.

    2. A002POVE01

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

      SST
      09612-30012

  46. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A002Q6N

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

  47. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A002LJH

      Remove the bolt from the front transaxle case.

    2. A002NK0E03

      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. A002NI3

      Remove the output shaft cover from the front transaxle case.

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


    1. A002PV7E03

      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. A002N5B

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING


    1. A002OCKE03

      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 TRANSAXLE CASE OIL SEAL LH


    1. A002P4Z

      Using a screwdriver, remove the transmission case oil seal from the manual transmission case.

      Tech Tips

      Tape the screwdriver tip before use.

  53. REMOVE FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE


    1. A002PEO

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

  54. REMOVE TRANSAXLE CASE OIL SEAL RH


    1. A002M6Y

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

      Tech Tips

      Tape the screwdriver tip before use.

  55. REMOVE FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE


    1. A002N6RE02

      Using SST, remove the front differential case front bearing outer race from the front transaxle case.

      SST
      09950-40011   ( 09951-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010 )
      09950-60010   ( 09951-00600 )