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


    1. A01KDSG

      Remove the clutch release fork boot from the front transaxle assembly.

  5. REMOVE CONTROL CABLE BRACKET


    1. A01KAJC

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

  6. REMOVE FLOOR SHIFT SELECTING BELL CRANK ASSEMBLY


    1. A01KB1D

      Remove the 2 bolts and floor shift selecting bell crank assembly from the manual transaxle assembly.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01KC1TN03

      Using SST, remove the back-up light switch assembly and gasket.

      SST
      09817-16011

  8. REMOVE NEUTRAL POSITION SWITCH

    A01KD0DN03

    1. Using SST, remove the neutral position switch and gasket.

      SST
      09817-16011

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01KDFR

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

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A01KCRX

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

  11. REMOVE SHIFT GATE PIN


    1. A01KBVM

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A01KDEI

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

  13. REMOVE SHIFT AND SELECT LEVER SHAFT STRAIGHT PIN


    1. A01KASMN01

      While pressing in the shift and select lever shaft straight pin (A) as far as it will go, pull out the shift and select lever shaft straight pin (B) to remove it.

    2. Remove the spring.

  14. REMOVE O-RING


    1. A01KCEC

      Remove the O-ring from the shift and select lever shaft straight pin (B).

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01KDA6

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

  16. REMOVE DRAIN PLUG


    1. A01KBNM

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

  17. REMOVE SHIFT DETENT BALL


    1. A01KCNM

      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 No. 1 shift detent ball spring seats, 4 shift detent ball compression springs and 4 shift detent balls.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01KBW1

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A01KBVR

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01KD5H

      Remove the 6 bolts from the front transaxle case.

    2. A01KCOX

      Remove the 12 bolts from the manual transmission case.

    3. A01KDGK

      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. A01KDC5

      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. A01KBFJ

      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. A01KBQB

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

    2. A01KDQC

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A01KCCB

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

    2. A01KBLU

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

    3. A01KD5NC04
      *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. A01KB6D

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A01KC18

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

    2. A01KCWZ

      Remove the pin from the shift arm.

    3. A01KDT7

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

    4. A01KD78

      Using a 5 mm pin punch and hammer, tap out the pin.

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

  27. REMOVE NO. 1 GEAR SHIFT FORK


    1. A01KD9R

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

  28. REMOVE SHIFT ARM


    1. A01KCBZ

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01KCK7

      Remove the bolt from the reverse shift fork.

    2. A01KCY1

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

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A01KCY5

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

    2. A01KCN9

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

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A01KC73

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

  32. REMOVE REVERSE SHIFT FORK


    1. A01KCS3

      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. A01KBOZ

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

    2. A01KC57

      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 ASSEMBLY AND NO. 2 OUTPUT SHAFT ASSEMBLY


    1. A01KCC8

      Remove the 3 shafts at the same time.

      Note

      Do not drop the input shaft, No. 1 output shaft assembly and No. 2 output shaft assembly.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01KAY8

      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. A01KAW8

      Remove the front differential case assembly from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A01KBKD

      Remove the transmission magnet from the front transaxle case.

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


    1. A01KD7QC01
      *a Turn
      *b Hold

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

      SST
      09387-00041   ( 09387-02020 )

  41. REMOVE REAR OUTPUT SHAFT BEARING SHIM


    1. A01KBJP

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A01KBO9N01

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

      SST
      09387-00041   ( 09387-01021, 09387-01030 )
      09527-20011
      09612-65014

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A01KCP8N02

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

      SST
      09387-00041   ( 09387-01021, 09387-01030 )
      09612-65014

  44. REMOVE REAR INPUT AND OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01KAY5

      Using a snap ring expander, remove the rear input and output shaft bearing shaft snap rings.

  45. REMOVE FRONT INPUT SHAFT BEARING


    1. A01KCHW

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. A01KBBBC01
      *a Turn
      *b Hold

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

      SST
      09612-30012

  46. REMOVE TRANSAXLE CASE OIL SEAL


    1. A01KDS2C01
      *a Protective Tape

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

      Note

      Do not damage the installation surface of the front transmission case.

      Tech Tips

      Tape the screwdriver tip before use.

  47. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A01KB2K

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. A01KAYGC01
      *a Turn
      *b Hold

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

      SST
      09612-65014   ( 09612-01020 )

  48. REMOVE OUTPUT SHAFT COVER


    1. A01KAVU

      Remove the output shaft cover from the front transaxle case.

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


    1. A01KAOCC01
      *a Turn
      *b Hold

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

      SST
      09387-00041   ( 09387-02020 )

  50. REMOVE OUTPUT SHAFT COVER


    1. A01KCSD

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE MANUAL TRANSMISSION CASE STRAIGHT PIN


    1. A01KAZV

      Remove the 4 manual transmission case straight pin.

  52. REMOVE SHIFT FORK SHAFT BEARING


    1. A01KCB4N02

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

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

  53. REMOVE TRANSMISION CASE OIL SEAL

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  54. REMOVE FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A01KDPV

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

  55. REMOVE TRANSAXLE CASE OIL SEAL

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  56. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01KCLUN02

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

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