MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A002LYI

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A002PQT

      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. A002P76

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

  4. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A002QR9

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

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A002PQH

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

  6. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A002P2N

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

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  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. A002QSK

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE TRANSMISSION CASE PLUG


    1. A002PB0

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

  13. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A002MIZ

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

  14. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A002N7B

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

  15. REMOVE LOCK BALL PIN


    1. A002OHH

      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.

  16. REMOVE SHIFT DETENT BALL


    1. A002NI7

      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. A002MEZ

      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.

  17. REMOVE OUTER SHIFT LEVER E RING


    1. A002OJY

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

  18. REMOVE MANUAL TRANSMISSION CASE


    1. A002LJW

      Remove the 16 bolts.

    2. A002QF6E01
      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. A002M83E01
      Text in Illustration
      *1 Boss

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

    4. A002MPH

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

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A002P5U

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A002NXZ

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

  21. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A002QKL

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A002N69

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

    2. A002PTH

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

  23. REMOVE OUTER SELECT LEVER


    1. A002O0IE01
      Text in Illustration
      *1 Mark

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

  24. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A002NDNE02
      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.

  25. REMOVE INPUT SHAFT ASSEMBLY


    1. A002QNO

      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.

  26. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A002LR6

      Remove the differential case assembly from the front transaxle case.

  27. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A002OVVE01

      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. A002QA9E14
      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 )

  28. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A002LY4E04

      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. A002NXDE02
      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 )

  29. REMOVE TRANSMISSION MAGNET


    1. A002PZA

      Remove the transmission magnet from the front transaxle case.

  30. REMOVE TRANSMISSION OIL SEPARATOR


    1. A002QTI

      for Front Transaxle Case Side:

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

  31. REMOVE BREATHER PLUG


    1. A002O0L

      Remove the breather plug from the front transaxle case.

  32. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A002OYZE02

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

      SST
      09308-00010
    2. A002Q9D

      Remove the output shaft cover from the front transaxle case.

  33. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A002MX6E02

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

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

  34. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A002QDJ

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

  35. REMOVE STRAIGHT PIN


    1. A002O4E

      Remove the 5 straight pins from the front transaxle case.

  36. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A002QOR

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

  37. REMOVE INPUT SHAFT COVER


    1. A002OF5

      Remove the input shaft cover from the manual transmission case.

  38. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A002NJJ

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

  39. REMOVE TRANSMISSION OIL SEPARATOR


    1. A002P8L

      For manual transmission case side:

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

  40. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A002N82

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

  41. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A002LHA

      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.

  42. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A002NSOE02
      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.

  43. REMOVE REAR OUTPUT SHAFT BEARING


    1. A002MX8E06

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

      SST
      09308-00010

  44. REMOVE TRANSMISSION CASE OIL SEAL


    1. A002Q1BE01

      Using SST, remove the transmission case oil seal from the manual transmission case.

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

  45. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A002NNHE01

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

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