MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A003COA

      Remove the clutch release fork with the clutch release bearing from the manual transaxle assembly.

  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. A003DC0

      Remove the clutch release bearing and clip from the clutch release fork.

  3. REMOVE RELEASE FORK SUPPORT


    1. A003EAH

      Remove the release fork support from the manual transaxle assembly.

  4. REMOVE CLUTCH RELEASE FORK BOOT


    1. A00E927

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

  5. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A00E6ZN

      Remove the 3 bolts and support bracket from the manual transaxle.

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A00E7IG

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00EA94E02

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

      SST
      09816-30010

  8. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A00E9N9E01

      Using SST, remove the park/neutral position switch and gasket.

      SST
      09816-30010

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A00E9K6

      Remove the lock ball from the manual transmission case.

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A00E77J

      Remove the lock ball from the manual transmission case.

  11. REMOVE SHIFT GATE PIN


    1. A00EAZO

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A00E894

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

  13. REMOVE SHIFT AND SELECT PIN


    1. A00EAAH

      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. A00E719E01

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A00E90S

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

  16. REMOVE DRAIN PLUG


    1. A00E74K

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

  17. REMOVE BALL


    1. A00EAL8

      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 balls.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A00EARV

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A00EAZ6E01

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A00E7YQ

      Remove the 6 bolts from the front transaxle case side.

    2. A00EAFR

      Remove the 12 bolts from the manual transmission case side.

    3. A00EAR6

      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. A00EAVW

      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. A00EAIGE01

      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. A00E8QP

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

    2. A00EAPY

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A00EB3W

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

    2. A00EAEY

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

    3. A00E76DE03
      Text in Illustration
      *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. A00E7CI

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A00EAIQ

      Using a screwdriver, remove the E-ring from the front transaxle case.

    2. A00E8Y4

      Remove the pin from the front transaxle case.

    3. A00E96G

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

    4. A00E6ZY

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

    5. Remove the No. 3 gear shift head.

  27. REMOVE NO. 1 GEAR SHIFT FORK


    1. A00E8LI

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

  28. REMOVE SHIFT ARM


    1. A00E6QO

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT


    1. A00E86O

      Remove the bolt from the reverse shift fork.

    2. A00E7M1

      Remove the reverse shift fork shaft.

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A00E943

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

    2. A00E8SL

      Remove the 5th and 6th shift fork shaft.

  31. REMOVE NO. 3 GEAR SHIFT FORK


    1. A00E7UZ

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

  32. REMOVE REVERSE SHIFT FORK


    1. A00EA8R

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

  33. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE


    1. A003DNQ

      Using a feeler gauge, measure the reverse idler gear thrust clearance.

      Standard clearance
      0.40 to 1.05 mm (0.00158 to 0.0413 in.)
      Maximum clearance
      1.05 mm (0.0413 in.)

      If the clearance is more than the maximum, replace the reverse idler gear, needle roller bearing and reverse idler gear shaft.

  34. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A003E5T

      Using a dial indicator, measure the reverse idler gear radial clearance.

      Standard clearance
      0.015 to 0.048 mm (0.000591 to 0.00188 in.)
      Maximum clearance
      0.048 mm (0.00188 in.)

      If the clearance is more than the maximum, replace the reverse idler gear, needle roller bearing and reverse idler gear shaft.

  35. REMOVE REVERSE IDLER GEAR


    1. A00E9OZE01

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

    2. A00E7X8

      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. A00E8RO

      Remove the 3 shafts at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR


    1. A00E7ZAE02

      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. A00E6LT

      Remove the differential case from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET


    1. A00EAL3

      Remove the transmission magnet from the front transaxle case.

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


    1. A00EA2XE01

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

      SST
      09387-00041   ( 09387-02020 )

  41. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A00E9CA

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

  42. REMOVE SHIFT FORK SHAFT BEARING


    1. A00EASEE01

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

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

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A00E9LCE01

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

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

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


    1. A00E8EP

      Using snap ring expander, remove the 2 snap rings.

  45. REMOVE INPUT SHAFT FRONT BEARING


    1. A00EA4Y

      Remove the bolt from the front transaxle case.

    2. A00E965E01

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

      SST
      09612-30012

  46. REMOVE TRANSAXLE CASE OIL SEAL


    1. A00E9C3

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

  47. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A00E9UT

      Remove the bolt from the front transaxle case.

    2. A00E6MKE01

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

      SST
      09612-65014   ( 09612-01020 )

  48. REMOVE OUTPUT SHAFT COVER


    1. A00E7YL

      Remove the output shaft cover from the front transaxle case.

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


    1. A00E97DE01

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

      SST
      09387-00041   ( 09387-02020 )

  50. REMOVE OUTPUT SHAFT COVER


    1. A00E9JI

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING


    1. A00E8MWE01

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

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

  52. REMOVE TRANSMISSION CASE OIL SEAL


    1. A00E9SR

      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 OUTER RACE BEARING


    1. A00E8TE

      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.

  54. REMOVE TRANSAXLE CASE OIL SEAL


    1. A00E7IE

      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 TAPERED ROLLER BEARING


    1. A00E9D6E01

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

      SST
      09387-00041   ( 09387-02020 )