MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A00DPR7

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A00DUCU

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

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00DS90

      Using a 27 mm deep socket wrench, remove the back-up light switch and gasket from the manual transmission case.

  4. REMOVE NEUTRAL POSITION SWITCH


    1. A00DQTL

      Using a 27 mm deep socket wrench, remove the neutral position switch and gasket from the manual transmission case.

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A00DQZ4

      Remove the 3 bolts and control cable bracket from the manual transmission case.

  6. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG


    1. Remove the bleeder plug from the clutch release bleeder sub-assembly.

  8. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    A005UWV

    1. Using a union nut wrench, remove the clutch release bleeder tube.

  9. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    A005SBD

    1. Using a union nut wrench, separate the clutch release bleeder sub-assembly from the clutch release cylinder to bleeder tube.

    2. Remove the 2 bolts and clutch release bleeder sub-assembly from the manual transaxle assembly.

  10. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A005W0W

      Remove the clutch tube boot from the manual transaxle assembly.

    2. A005RZY

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

    3. A005UQ8

      Using a union nut wrench, remove the clutch release cylinder to bleeder tube from the clutch release with bearing cylinder assembly.

  11. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A00DQAO

      Place the manual transaxle on wooden blocks.

  12. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A00DT80

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

  13. REMOVE LOCK BALL PIN


    1. A00DQMM

      Using a 10 mm hexagon socket wrench, 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.

    3. A00DUV6

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

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

  14. REMOVE SHIFT DETENT BALL


    1. A00DR1R

      Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the manual transmission case.

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

    3. A00DUC1

      Using a 6 mm, hexagon socket wrench, remove the 2 shift detent ball plugs from the manual transmission case.

    4. Using a magnet hand, remove the 2 compression springs and 2 shift detent balls from the manual transmission case.

  15. REMOVE OUTER SHIFT LEVER E-RING


    1. A00DRFF

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

  16. REMOVE MANUAL TRANSMISSION CASE


    1. A00DQU4

      Remove the 17 bolts.

    2. A00DSBKE01
      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. A00DUIV

      Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.

    4. A00DPOF

      Push the outer No. 1 shift lever and remove the manual transmission case.

  17. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00DT06

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

  18. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A00DUUN

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

  19. REMOVE REVERSE SHIFT FORK


    1. A00DQ2P

      Using a 5 mm pin punch and hammer, tap out the reverse shift fork slotted spring pin.

    2. Remove the reverse shift fork from the reverse shift fork shaft.

  20. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A00DSGB

      Using a 6 mm hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket from the front transaxle case.

  21. REMOVE OUTER SELECT LEVER


    1. A00DTOD

      Remove the inner select lever bolt.

    2. A00DQEW

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A00DRXS

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

  23. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A00DTKME01
      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.

  24. REMOVE INPUT SHAFT ASSEMBLY


    1. A00DPY7

      Remove the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.

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

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

    4. Remove the No. 2 gear shift fork shaft assemblies from the input shaft assembly.

  25. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A00DQMY

      Remove the differential case from the front transaxle case.

  26. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A00DUZ3E01

      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. A00DV0YE01
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the differential case assembly 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   ( 09951-00350, 09951-00550, 09952-06010 )

  27. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00DQ0TE01

      Using SST, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.

      SST
      09308-00010
    2. A00DTVJE01
      Text in Illustration
      *1 Turn
      *2 Hold

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00350, 09951-00550, 09952-06010 )

  28. REMOVE TRANSMISSION MAGNET


    1. A00DU9W

      Remove the transmission magnet from the front transaxle case.

  29. REMOVE BREATHER PLUG


    1. A00DTSS

      Remove the breather plug from the front transaxle case.

  30. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A00DSQGE01

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

      SST
      09308-00010
    2. A00DU01

      Remove the output shaft cover from the front transaxle case.

  31. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A00DTR1E01

      Using SST, tap out the front transaxle case oil seal from the front transaxle case.

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

  32. REMOVE STRAIGHT PIN


    1. A00DU3U

      Remove the 5 straight pins from the front transaxle case.

  33. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A00DR1V

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

  34. REMOVE INPUT SHAFT COVER


    1. A00DQAC

      Remove the input shaft cover from the manual transmission case.

  35. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A00DRJJ

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

  36. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A00DSKY

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

      Tech Tips

      When removing the slotted spring pin, align the pin with the hole in the 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.

  37. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A00DTKM

      Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the front transaxle case.

      Note

      Do not damage the installation surfaces.

  38. REMOVE REAR OUTPUT SHAFT BEARING


    1. A00DSJLE01

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

      SST
      09308-00010

  39. REMOVE TRANSMISSION CASE OIL SEAL


    1. A00DPKFE01

      for LH side:


      1. Using SST, remove the transmission case oil seal from the manual transmission case.

        SST
        09308-00010
    2. A00DT8SE01

      for RH side:


      1. Using SST, remove the transmission case oil seal from the front transaxle case.

        SST
        09308-00010