MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A005J5T

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A005M66

      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. A005LZB

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

  4. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A005GVV

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

  5. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  9. REMOVE CLUTCH TUBE BOOT

  10. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  11. REMOVE BLEEDER CLUTCH RELEASE TUBE

    Click here

  12. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A005M9UE03
      Text in Illustration
      *1 Wooden Blocks

      Place the manual transaxle assembly on wooden blocks.

  13. REMOVE TRANSMISSION CASE PLUG


    1. A005IFK

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

  14. REMOVE TRANSMISSION CASE PLUG


    1. A005J17

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

  15. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A005LDP

      Using a deep socket wrench 24 mm, remove the No. 1 lock ball assembly from the manual transmission case.

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A005LOZ

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

  17. REMOVE LOCK BALL PIN


    1. A005GE6

      Using a socket hexagon 10 mm, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.

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

  18. REMOVE SHIFT DETENT BALL


    1. A005JHN

      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. A005LLN

      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.

  19. REMOVE OUTER SHIFT LEVER E RING


    1. A005KJR

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

  20. REMOVE MANUAL TRANSMISSION CASE


    1. A005IRA

      Remove the 16 bolts.

    2. A005LZME04
      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. A005J4YE04
      Text in Illustration
      *a Boss

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

    4. A005H7FE03
      Text in Illustration
      *a Push

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

  21. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A005IRO

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

  22. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A005M5G

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

  23. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A005GX3

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

  24. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A005KIZ

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

    2. A005IDZ

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

  25. REMOVE OUTER SELECT LEVER


    1. A005H3YE12
      Text in Illustration
      *1 Inner Select Lever
      *2 Outer Select Lever
      *a Position Mark

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

  26. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A005KYNE04
      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. A005JYY

      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. A005GMH

      Remove the differential case assembly from the front transaxle case.

  29. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A005HDDE01

      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. A005IQ7E09
      Text in Illustration
      *a Hold
      *b 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. A005L3WE02

      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. A005K5TE09
      Text in Illustration
      *a Hold
      *b 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. A005GOT

      Remove the transmission magnet from the front transaxle case.

  32. REMOVE TRANSMISSION OIL SEPARATOR


    1. A005JK8

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

  33. REMOVE BREATHER PLUG


    1. A005M10

      Remove the breather plug from the front transaxle case.

  34. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A005GYTE01

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

      SST
      09308-00010
    2. A005HCY

      Remove the output shaft cover from the front transaxle case.

  35. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A005JWBE03

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

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

  36. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A005MA4

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

  37. REMOVE STRAIGHT PIN


    1. A005K9J

      Remove the 5 straight pins from the front transaxle case.

  38. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A005KAU

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

  39. REMOVE INPUT SHAFT COVER


    1. A005GS8

      Remove the input shaft cover from the manual transmission case.

  40. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A005GU5

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

  41. REMOVE TRANSMISSION OIL SEPARATOR


    1. A005KV8

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

  42. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A005LUS

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

  43. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A005JJ4E04
      Text in Illustration
      *1 Slotted Spring Pin
      *2 Inner No. 1 Shift Lever
      *3 Outer No. 1 Shift Lever
      *a Mark

      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. A005GTKE05
      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. A005KINE03

      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. A005GXUE03

      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. A005K6DE03

      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 )