БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ РАЗБОРКА

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. A00Y6NS

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

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A00YA7W

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00Y7OYN01

      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. A00Y7AAN01

      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. A00Y95J

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

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A00Y703

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

  11. REMOVE SHIFT GATE PIN


    1. A00Y82I

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A00YA2L

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

  13. REMOVE SHIFT AND SELECT PIN


    1. A00YBGLC01
      *a Press and hold
      *b Pull out the shift and select pin.

      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. A00Y9Z2C01
      *1 O-ring

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A00Y86O

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

  16. REMOVE DRAIN PLUG


    1. A00Y65E

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

  17. REMOVE SHIFT DETENT BALL


    1. A00Y94O

      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. A00Y96Z

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A00YAZB

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A00Y7Q7

      Remove the 6 bolts from the front transaxle case side.

    2. A00Y6V5

      Remove the 12 bolts from the manual transmission case side.

    3. A00Y7HR

      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. A00Y77D

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

      Note

      Do not damage the No. 1 oil receiver pipe.

  22. REMOVE TRANSMISSION OIL SEPARATOR


    1. A00Y507

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

  23. REMOVE 1ST AND 2ND SHIFT FORK SHAFT


    1. A00YAY4

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

    2. A00Y5HE

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

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A00Y5UO

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

    2. A00Y9Q8

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

    3. A00Y8SEC05
      *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 from the front transaxle case.

  25. REMOVE NO. 2 GEAR SHIFT FORK


    1. A00Y6DP

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A00Y96N

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

    2. A00Y6UZ

      Remove the pin from the shift arm.

    3. A00Y9MG

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

    4. A00Y8JA

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

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

  27. REMOVE NO. 1 GEAR SHIFT FORK


    1. A00YB8X

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

  28. REMOVE SHIFT ARM


    1. A00Y6HB

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A00Y59S

      Remove the bolt of the reverse shift fork shaft.

    2. A00Y663

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

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A00YAEY

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

    2. A00Y4YQ

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

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A00Y8UW

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

  32. REMOVE REVERSE SHIFT FORK


    1. A00Y5V8

      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

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  35. REMOVE REVERSE IDLER GEAR


    1. A00YAKH

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

    2. A00Y5WI

      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. A00Y4WH

      Remove the 3 shafts at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A00Y598

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

  38. REMOVE DIFFERENTIAL GEAR ASSEMBLY


    1. A00Y7VJ

      Remove the differential gear assembly from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A00Y60M

      Remove the transmission magnet from the front transaxle case.

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


    1. A00Y7CQN01

      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. A00Y5F0

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A00Y4YJN01

      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. A00Y9WUN01

      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. A00Y5K8

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

  45. REMOVE INPUT SHAFT FRONT BEARING


    1. A00Y85A

      Remove the bolt from the front transaxle case.

    2. A00Y5HWN01

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

      SST
      09612-30012
  46. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A00Y9BV

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

  47. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A00Y6NC

      Remove the bolt from the front transaxle case.

    2. A00YB5MN01

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

      SST
      09612-65014   ( 09612-01020 )
  48. REMOVE OUTPUT SHAFT COVER


    1. A00Y85K

      Remove the output shaft cover from the front transaxle case.

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


    1. A00YAJCN01

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

      SST
      09387-00041   ( 09387-02020 )
  50. REMOVE OUTPUT SHAFT COVER


    1. A00YAB7

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING


    1. A00Y8T6N01

      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. A00Y7W5

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

  53. REMOVE FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE


    1. A00Y69H

      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. A00Y7BW

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

  55. REMOVE FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE


    1. A00Y5KJN01

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

      SST
      09387-00041   ( 09387-02020 )