MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A011AAJ

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A0119GI

      Using a socket hexagon 10 mm, remove the manual transmission drain plug and gasket from the front transaxle case.

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A011ASV

      Disengage the wire harness clamp of the back-up light switch assembly.

    2. A0119D6E01

      Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

      SST
      09817-16011

  4. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A011A1R

      Remove the bolt and wire harness clamp bracket from the front transaxle case.

    2. A01187V

      Remove the bolt and wire harness clamp bracket from the manual transmission case.

  5. REMOVE NO. 1 CLUTCH HOUSING COVER

    A011BPN

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

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    A0119X3

    1. Using a union nut wrench 10 mm, separate the clutch release bleeder from the bleeder clutch release tube.

    2. Remove the 2 bolts and clutch release bleeder.

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  8. REMOVE CLUTCH TUBE BOOT


    1. Remove the clutch tube boot from the transaxle.

  9. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    A0119UV

    1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.

  10. REMOVE BLEEDER CLUTCH RELEASE TUBE

    A011BWO

    1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.

  11. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A0117E3E01
      Text in Illustration
      *1 Wooden blocks

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE NO. 1 TRANSMISSION CASE PLUG


    1. A0118PP

      Using a 30 mm socket wrench, remove the No. 1 transmission case plug and gasket.

  13. REMOVE TRANSMISSION CASE PLUG


    1. for manual transmission case upper side


      1. A0118US

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

    2. for manual transmission case rear side


      1. A011B88

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

  14. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A0117MI

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

  15. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A011971

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

  16. REMOVE LOCK BALL PIN


    1. A011A2W

      Using a socket hexagon 10 mm, remove the plug from the manual transmission case.

    2. Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.

  17. REMOVE SHIFT DETENT BALL


    1. A011BLF

      Using a socket hexagon 6 mm, 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. A0116Y1

      Using a socket hexagon 6 mm, 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.

  18. REMOVE OUTER SHIFT LEVER E RING


    1. A011B4U

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A011ABF

      Remove the 16 bolts.

    2. A011A0QE01
      Text in Illustration
      *1 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. A0118H0E03
      Text in Illustration
      *1 Outer No. 1 shift lever
      *2 Push
      *3 Turn

      Push the outer No. 1 shift lever.

    4. Turn the outer No. 1 shift lever counterclockwise and remove the manual transmission case.

  20. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A0118OXE02
      Text in Illustration
      *1 Reverse idler gear shaft
      *2 Thrust washer
      *3 Reverse idler gear sub-assembly

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

  21. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A011A3P

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

  22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A011B0N

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

  23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A011BKS

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

  24. REMOVE SHIFT INTER LOCK PLATE


    1. A0118RT

      Remove the shift inter lock plate.

  25. REMOVE OUTER SELECT LEVER


    1. A0117MT

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

    2. A011AP4E01
      Text in Illustration
      *1 Inner select lever
      *2 Outer select lever

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

  26. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A011AJEE01
      Text in Illustration
      *1 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.

  27. REMOVE INPUT SHAFT ASSEMBLY


    1. A0119HC

      Remove the input shaft assembly, output shaft assembly and 3 gear shift fork shaft assemblies from the front transaxle case.

  28. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A011BM2

      Remove the differential case assembly from the front transaxle case.

  29. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01186ME01
      Text in Illustration
      *1 Front differential case front tapered roller bearing (outer race)
      *2 Front differential case front plate washer

      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. A0119TZE05
      Text in Illustration
      *1 Hold
      *2 Turn

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

  30. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A011BI4E01
      Text in Illustration
      *1 Front differential case rear tapered roller bearing (outer race)
      *2 Front differential case rear plate washer

      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. A011724E03
      Text in Illustration
      *1 Hold
      *2 Turn

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00390 )

  31. REMOVE TRANSMISSION MAGNET


    1. A0118BM

      Remove the transmission magnet from the front transaxle case.

  32. REMOVE TRANSMISSION OIL SEPARATOR


    1. A0119ZN

      Remove the 3 bolts and transmission oil separator from the front transaxle case.

  33. REMOVE FRONT OUTPUT SHAFT BEARING

    A01185CE01
    Text in Illustration
    *1 Front output shaft bearing (outer race)
    *2 Output shaft cover

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

      SST
      09308-00010

  34. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01174PE01

      Remove the front transaxle case oil seal from the front transaxle case.

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

  35. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A011B8E

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

  36. REMOVE STRAIGHT PIN


    1. A0119Y4

      Remove the 4 straight pins from the front transaxle case.

  37. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A0117AN

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

  38. REMOVE INPUT SHAFT COVER


    1. A0118FF

      Remove the input shaft cover from the manual transmission case.

  39. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A0118PK

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

  40. REMOVE NO. 1 TRANSMISSION OIL SEPARATOR


    1. A0118VK

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

  41. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A011BYB

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

  42. REMOVE NO. 2 TRANSMISSION OIL SEPARATOR


    1. A011901

      Remove the 2 bolts and No. 2 transmission oil separator.

  43. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A011BSR

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

      Tech Tips

      When removing the slotted spring pin, align the 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.

  44. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A0117KBE01
      Text in Illustration
      *1 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.

  45. REMOVE REAR OUTPUT SHAFT BEARING


    1. A0119QIE01
      Text in Illustration
      *1 Rear output shaft bearing (outer race)
      *2 Rear output shaft bearing shim

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

      SST
      09308-00010

  46. REMOVE TRANSMISSION CASE OIL SEAL


    1. A011B8XE01

      Remove the transmission case oil seal from the manual transmission case.

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

  47. REMOVE TRANSAXLE CASE OIL SEAL


    1. A011778E01

      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 )

  48. REMOVE BREATHER PLUG


    1. A0117JE

      Remove the breather plug from the front transaxle case.