MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A00DRIS

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A00DRQP

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

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00DU9R

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A00DS5Y

      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. A00DQZ3

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

  6. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A00DTAT

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

  7. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A00DV0F

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

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  10. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    A005SOR

    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.

  11. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A005SHY

      Remove the clutch tube boot from the manual transaxle assembly.

    2. A005TN0

      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.

  12. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A00DPQ2

      Place the manual transaxle assembly on wooden blocks.

  13. REMOVE TRANSMISSION CASE PLUG


    1. A00DRCH

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

  14. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A00DPO1

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

  15. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A00DPZK

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

  16. REMOVE LOCK BALL PIN


    1. A00DUA8

      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.

  17. REMOVE SHIFT DETENT BALL


    1. A00DTEB

      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. A00DPMZ

      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.

  18. REMOVE OUTER SHIFT LEVER E RING


    1. A00DQKT

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

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A00DQ2T

      Remove the 16 bolts.

    2. A00DQ5IE01
      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. A00DU7OE01
      Text in Illustration
      *1 Boss

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

    4. A00DTGQ

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

  20. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00DR4S

      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. A00DV0W

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

  22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A00DQSG

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

  23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A00DTQZ

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

    2. A00DQDQ

      Turn the shift and select lever shaft assembly and shift inter lock plate clockwise and remove them from the front transaxle case.

  24. REMOVE OUTER SELECT LEVER


    1. A00DSWS

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

  25. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A00DTG4E01
      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.

  26. REMOVE INPUT SHAFT ASSEMBLY


    1. A00DQ9N

      Remove the input shaft assembly, output shaft assembly and 3 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 and No. 3 gear shift fork shaft assemblies from the input shaft assembly.

  27. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A00DTMC

      Remove the differential case assembly from the front transaxle case.

  28. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A00DQHBE01

      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. A00DQCXE04
      Text in Illustration
      *1 Turn
      *2 Hold

      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 )

  29. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00DSRME01

      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. A00DR8IE02
      Text in Illustration
      *1 Turn
      *2 Hold

      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 )

  30. REMOVE TRANSMISSION MAGNET


    1. A00DSYK

      Remove the transmission magnet from the front transaxle case.

  31. REMOVE TRANSMISSION OIL SEPARATOR


    1. A00DQTO

      For front transaxle case side:

      Remove the 4 bolts and transmission oil separator from the front transaxle case.

  32. REMOVE BREATHER PLUG


    1. A00DT6B

      Remove the breather plug from the front transaxle case.

  33. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A00DSXCE01

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

      SST
      09308-00010
    2. A00DQE5

      Remove the output shaft cover from the front transaxle case.

  34. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A00DRNUE01

      Using SST, 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. A00DTX3

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

  36. REMOVE STRAIGHT PIN


    1. A00DTW2

      Remove the 5 straight pins from the front transaxle case.

  37. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A00DR10

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

  38. REMOVE INPUT SHAFT COVER


    1. A00DPUGE01

      Remove the input shaft cover from the manual transmission case.

  39. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A00DR9K

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

  40. REMOVE TRANSMISSION OIL SEPARATOR


    1. A00DU6T

      For manual transmission case side:

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

  41. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A00DPQQ

      Remove the 4 bolts and manual transmission oil separator sub-assembly from the manual transmission case.

  42. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A00DQYV

      Using a 5 mm pin punch and 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.

  43. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A00DQJ1E02
      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 front transaxle case.

      Note

      Do not damage the installation surfaces.

  44. REMOVE REAR OUTPUT SHAFT BEARING


    1. A00DQWME01

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

      SST
      09308-00010

  45. REMOVE TRANSMISSION CASE OIL SEAL


    1. A00DS44E01

      for LH side:


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

        SST
        09950-60010   ( 09951-00620 )
        09950-70010   ( 09951-07150 )
    2. A00DV0RE01

      for RH side:


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

        SST
        09950-60010   ( 09951-00530 )
        09950-70010   ( 09951-07150 )