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


    1. A01QSE6

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

  5. REMOVE CONTROL CABLE BRACKET


    1. A01QTQK

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

  6. REMOVE FLOOR SHIFT SELECTING BELL CRANK ASSEMBLY


    1. A01QPTV

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01QOA2N01

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

      SST
      09817-16011

  8. REMOVE NEUTRAL POSITION SWITCH

    A01QSVXN01

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

      SST
      09817-16011

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01QOPE

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

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A01QPZV

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

  11. REMOVE SHIFT GATE PIN


    1. A01QODR

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A01QPML

      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. A01QQ4EN01

      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. A01QRUT

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01QO8W

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

  16. REMOVE DRAIN PLUG


    1. A01QPWN

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

  17. REMOVE SHIFT DETENT BALL


    1. A01QTT9

      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. A01QS3J

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A01QQDW

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A01QTOE

      Remove the 6 bolts from the front transaxle case.

    2. A01QO9T

      Remove the 12 bolts from the manual transmission case.

    3. A01QSAQ

      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. A01QU85

      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. A01QOHT

      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. A01QP80

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

    2. A01QR3Q

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A01QPYT

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

    2. A01QP78

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

    3. A01QSVBC04
      *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. A01QSTL

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A01QP7R

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

    2. A01QSL7

      Remove the pin from the shift arm.

    3. A01QOPI

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

    4. A01QRFC

      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. A01QQFZ

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

  28. REMOVE SHIFT ARM


    1. A01QP7O

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01QONQ

      Remove the bolt from the reverse shift fork.

    2. A01QTIY

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

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A01QSKS

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

    2. A01QQDY

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

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A01QR9P

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

  32. REMOVE REVERSE SHIFT FORK


    1. A01QOL6

      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. A01QT2P

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

    2. A01QSJG

      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. A01QPR2

      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. A01QRC5

      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. A01QUKF

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

  39. REMOVE TRANSMISSION MAGNET


    1. A01QUIL

      Remove the transmission magnet from the front transaxle case.

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


    1. A01QRUXC01
      *a Turn
      *b Hold

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

      SST
      09387-00041   ( 09387-02020 )

  41. REMOVE REAR OUTPUT SHAFT BEARING SHIM


    1. A01QRWS

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A01QS2WN01

      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. A01QQIEN02

      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. A01QTNS

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

  45. REMOVE FRONT INPUT SHAFT BEARING


    1. A01QQ31

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

    2. A01QRJ0C01
      *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. A01QR3YC01
      *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. A01QPE8

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

    2. A01QSB0C01
      *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. A01QRG7

      Remove the output shaft cover from the front transaxle case.

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


    1. A01QOUMC01
      *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. A01QOEC

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE MANUAL TRANSMISSION CASE STRAIGHT PIN


    1. A01QQ98

      Remove the 4 manual transmission case straight pins.

  52. REMOVE SHIFT FORK SHAFT BEARING


    1. A01QPLVN02

      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 TRANSMISSION CASE OIL SEAL

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  54. REMOVE FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A01QSCL

      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. A01QTBPC01
      *a Turn
      *b Hold

      Using SST, remove the front differential case front tapered roller bearing from the front transaxle case.

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