MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  3. REMOVE RELEASE FORK SUPPORT

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  4. REMOVE CLUTCH RELEASE FORK BOOT

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  5. REMOVE CONTROL CABLE BRACKET


    1. A01M1JR

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

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A01LX6H

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01M0YNN01

      Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

      SST
      09816-30010

  8. REMOVE NEUTRAL POSITION SWITCH


    1. A01LVL4N01

      Using SST, remove the neutral position switch and gasket from the manual transmission case.

      SST
      09816-30010

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01M2UR

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

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A01LWO7

      Remove the No. 2 lock ball assembly from the manual transmission case.

  11. REMOVE SHIFT GATE PIN


    1. A01LXUJ

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY

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  13. REMOVE SHIFT AND SELECT PIN


    1. A01M39VC01
      *a Press and hold
      *b Pull out the shift and select pin
      *c Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the spring.

  14. REMOVE O-RING


    1. A01M0Y7C02
      *1 O-ring
      *2 Shift and Select Pin

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01LVV4

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

  16. REMOVE DRAIN PLUG


    1. A01LXAQ

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

  17. REMOVE SHIFT DETENT BALL


    1. A01M0GUC01
      *1 Shift Detent Ball
      *2 Spring
      *3 Spring Seat

      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 shift detent balls from the front transaxle case.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01M3HS

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A01LYRC

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01LV6B

      Remove the 6 bolts from the manual transmission case.

    2. A01LYAN

      Remove the 12 bolts and manual transmission case from the front transaxle case.

    3. A01LXJQ

      Use 2 snap ring pliers to keep the snap ring stretched and remove the manual transmission case.

  21. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01M06X

      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. A01LWX4

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

  23. REMOVE 1ST AND 2ND SHIFT FORK SHAFT


    1. A01LUYP

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

    2. A01LUWB

      Remove the 1st and 2nd shift fork shaft from the front transaxle case.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A01LWFT

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 2 gear shift head.

    2. A01M0I3

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 2 gear shift fork.

    3. A01LZBC

      Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head from the front transaxle case.

  25. REMOVE NO. 2 GEAR SHIFT FORK


    1. A01M2VK

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A01M1Q0C01
      *1 E-ring
      *2 Pin

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

    2. A01LWOY

      Remove the pin from the shift arm.

    3. A01LWOW

      Remove the shift arm from the No. 5 gear shift fork shaft.

    4. A01LYTV

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

    5. A01LWJYC01
      *1 No. 3 Gear Shift Head
      *2 No. 5 Gear Shift Fork Shaft

      Using a 5 mm pin punch and hammer, remove the slotted spring pin from the No. 3 gear shift head.

    6. Remove the No. 3 gear shift head from the No. 5 gear shift fork shaft.

  27. REMOVE NO. 1 GEAR SHIFT FORK


    1. A01M1XV

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

  28. REMOVE SHIFT ARM


    1. A01LZ5L

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01M1Z7

      Remove the bolt from the reverse shift fork shaft.

    2. A01M085

      Remove the reverse shift fork shaft from the front transaxle case.

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A01M1CA

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

    2. A01LZFS

      Remove the 5th and 6th shift fork shaft from the front transaxle case.

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A01LZS6

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

  32. REMOVE REVERSE SHIFT FORK


    1. A01LZHQ

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

  33. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

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  34. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

    Click here

  35. REMOVE REVERSE IDLER GEAR


    1. A01LYXU

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

    2. A01M11UC01
      *1 Reverse Idler Gear
      *2 Needle Roller Bearing
      *3 Reverse Idler Thrust Washer
      *4 Reverse Idler Gear Shaft

      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. A01LV1E

      Remove the input shaft assembly, No. 1 output shaft assembly and No. 2 output shaft assembly at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01M2VO

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

  38. REMOVE DIFFERENTIAL GEAR ASSEMBLY


    1. A01LZ6B

      Remove the differential gear assembly from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A01LV2E

      Remove the transmission magnet from the front transaxle case.

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


    1. A01LZVIN02

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

      SST
      09387-00041   ( 09387-02020 )

  41. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A01LXVM

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A01M2A3N03

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

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

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A01LVWWN01

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

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

  44. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A01LXC7C01
      *1 Input Shaft Rear Bearing Shaft Snap Ring
      *2 Output Shaft Rear Bearing Shaft Snap Ring

      Using snap ring pliers, remove the input shaft rear bearing shaft snap ring from the manual transmission case.

    2. Using snap ring pliers, remove the output shaft rear bearing shaft snap ring from the manual transmission case.

  45. REMOVE INPUT SHAFT FRONT BEARING


    1. A01LWNL

      Remove the bolt from the front transaxle case.

    2. A01M2O6N02

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

      SST
      09612-30012

  46. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01LZIGC01
      *a Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A01LVCZC01
      *a Turn
      *b Hold

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

      SST
      09387-00041   ( 09387-02020 )

  48. REMOVE OUTPUT SHAFT COVER


    1. A01LV6V

      Remove the output shaft cover from the front transaxle case.

  49. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01M07Y

      Remove the bolt from the front transaxle case.

    2. A01M1LCN01

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

      SST
      09612-65014   ( 09612-01020 )

  50. REMOVE OUTPUT SHAFT COVER


    1. A01LWZY

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING


    1. A01LY2NN01

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

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

  52. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01LWTN

      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. A01LVY8

      Using a brass bar and a hammer, remove 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


    1. A01LYHS

      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. A01LVYFN01

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

      SST
      09387-00041   ( 09387-02020 )