MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01LZ71

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A01M0AG

      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. A01LVMZ

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

  4. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A01M1WA

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

  5. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A01LZWQ

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

  6. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  8. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  9. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  10. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  11. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A01M1FQC07
      *a Wooden Block

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE TRANSMISSION CASE PLUG


    1. A01LYLX

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

  13. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01LZ44

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

  14. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01LWO3

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

  15. REMOVE LOCK BALL PIN


    1. A01LYG9

      Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.

    2. Using a Magnet Hand, remove the shift and select lever shaft compression spring and lock ball pin from the manual transmission case.

  16. REMOVE SHIFT DETENT BALL


    1. A01LYFD

      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 shift detent ball compression spring and shift detent ball from the manual transmission case.

    3. A01LX1J

      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 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.

  17. REMOVE OUTER SHIFT LEVER E-RING


    1. A01LW7T

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

  18. REMOVE MANUAL TRANSMISSION CASE


    1. A01LZIJ

      Remove the 16 bolts.

    2. A01LZBEC06
      *a 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. A01LZVBC01
      *a Boss

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

    4. A01LVR7

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

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01LZR7

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01LX6O

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

  21. REMOVE REVERSE SHIFT FORK


    1. Secure the No. 4 gear shift fork shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01LXSG

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the reverse shift fork.

    3. A01M0V8

      Remove the reverse shift fork from the No. 4 gear shift fork shaft.

  22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01LUYH

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

  23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01M2AQ

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

    2. A01LZ17C01
      *1 Shift and Select Lever Shaft Assembly
      *2 Shift Inter Lock Plate

      Turn the shift and select lever shaft assembly clockwise and remove it from the front transaxle case.

    3. Remove the shift inter lock plate from the front transaxle case.

  24. REMOVE OUTER SELECT LEVER


    1. A01M1QJC04
      *a Mark

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

  25. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A01LVURC04
      *a 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. A01LXGH

      Remove the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly from the front transaxle case.

  27. REMOVE NO. 1 GEAR SHIFT HEAD


    1. Secure the No. 1 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01M0PV

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 1 gear shift head.

    3. A01M0HG

      Remove the No. 1 gear shift head from the No. 1 gear shift fork assembly.

  28. REMOVE NO. 2 GEAR SHIFT HEAD


    1. Secure the No. 2 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01M18M

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

    3. A01LX55

      Remove the No. 2 gear shift head from the No. 2 gear shift fork assembly.

  29. REMOVE NO. 2 REVERSE PRE-BALK HEAD


    1. A01LXY2C01
      *1 Snap Ring
      *a Protective Tape

      Using 2 screwdrivers with their tips wrapped with protective tape and a hammer, remove the snap ring from the No. 2 gear shift fork assembly.

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

    2. A01M333

      Remove the spacer from the No. 2 gear shift fork assembly.

    3. A01M1RA

      Remove the No. 2 reverse pre-balk head from the No. 2 gear shift fork assembly.

    4. Secure the No. 2 reverse pre-balk head in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    5. A01M3DC

      Using a 3 mm pin punch and a hammer, remove the straight pin from the No. 2 reverse pre-balk head.

    6. A01LX8OC02
      *1 Bimetal Formed Bushing
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape and a hammer, remove the 2 bimetal formed bushings from the No. 2 reverse pre-balk head.

      Note

      Do not damage the No. 2 reverse pre-balk head.

  30. REMOVE SHIFT LEVER STOPPER


    1. A01LV75

      Remove the torsion spring from the No. 2 gear shift fork assembly.

    2. A01LWDP

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

    3. A01M303

      Remove the shift lever stopper from the No. 2 gear shift fork assembly.

  31. REMOVE NO. 3 GEAR SHIFT HEAD


    1. Secure the No. 3 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01LXY9

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

    3. A01LXBK

      Remove the No. 3 gear shift head from the No. 3 gear shift fork assembly.

  32. REMOVE NO. 3 REVERSE PRE-BALK HEAD


    1. A01M01N

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 reverse pre-balk head.

    2. A01LXPU

      Remove the No. 3 reverse pre-balk head from the No. 3 gear shift fork assembly.

  33. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01M2NQ

      Remove the differential case assembly from the front transaxle case.

  34. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01M2OKN03

      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. A01M2AGC04
      *a Hold
      *b Turn

      Using SST, remove the front differential case front tapered roller bearing (inner race) 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 )

  35. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01M1MGN03

      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. A01LWCRC04
      *a Hold
      *b Turn

      Using SST, remove the front differential case rear tapered roller bearing (inner race) 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 )

  36. REMOVE TRANSMISSION MAGNET


    1. A01M0FK

      Remove the transmission magnet from the front transaxle case.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01M26N

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

  38. REMOVE BREATHER PLUG


    1. A01LVVC

      Remove the breather plug from the front transaxle case.

  39. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)


    1. A01M1Y5N03

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

      SST
      09308-00010
    2. A01M0W3

      Remove the output shaft cover from the front transaxle case.

  40. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01M1VFN03

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

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

  41. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01LXAX

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

  42. REMOVE STRAIGHT PIN


    1. A01M2JD

      Remove the 5 straight pins from the front transaxle case.

  43. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01LWXL

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

  44. REMOVE INPUT SHAFT COVER


    1. A01M156

      Remove the input shaft cover from the manual transmission case.

  45. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01LY38

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

  46. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01LYP2

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

  47. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A01LZ3N

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

  48. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A01M0N8

      Using a 5 mm pin punch and a hammer, remove the inner shift lever slotted spring pin from the inner No. 1 shift lever.

      Tech Tips

      When removing the inner shift lever slotted spring pin, align the inner shift lever slotted spring 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.

  49. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A01LV24C04
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the manual transmission case.

      Note

      Do not damage the installation surfaces.

  50. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)


    1. A01LZ23N06

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

      SST
      09308-00010

  51. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01M195N03

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

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

  52. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01LWIDN03

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

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