MULTI-MODE MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A005IEM

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A005KXV

      Using a socket hexagon wrench 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 TRANSMISSION REVOLUTION SENSOR


    1. A005MIG

      Remove the bolt and transmission revolution sensor.

    2. Remove the O-ring from the transmission revolution sensor.

  5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A005MG9

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

  6. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A005IJG

      Remove the 6 bolts and wire harness clamp bracket.

    2. A005H37E02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the shift and select actuator from the manual transmission case.

  7. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  8. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP


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

  10. REMOVE RELEASE CYLINDER BLEEDER PLUG


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

  11. REMOVE CLUTCH TUBE BOOT

  12. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  13. REMOVE BLEEDER CLUTCH RELEASE TUBE

    Click here

  14. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A005M6SE04
      Text in Illustration
      *1 Wooden Blocks

      Place the manual transaxle assembly on wooden blocks.

  15. REMOVE TRANSMISSION CASE PLUG


    1. A005K0D

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

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A005IGQ

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

  17. REMOVE SHIFT DETENT BALL


    1. A005KKG

      Using a socket hexagon wrench 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. A005MB6

      Using a socket hexagon wrench 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 MANUAL TRANSMISSION CASE


    1. A005IRA

      Remove the 16 bolts.

    2. A005KPPE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the manual transmission case from the front transaxle case.

      Note

      Do not damage the manual transmission case.

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A005GU7

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A005H0V

      Turn the reverse shift fork shaft assembly clockwise.

    2. A005J20

      Remove the reverse shift fork shaft assembly from the front transaxle case.

  21. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A005JO3

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A005KBN

      Turn the shift and select lever shaft assembly clockwise.

    2. A005K9F

      Remove the shift and select lever shaft assembly from the front transaxle case.

  23. REMOVE INNER NO. 2 SHIFT LEVER


    1. A005H2O

      Using a pin punch (5 mm) and a hammer, remove the slotted spring pin and inner No. 2 shift lever.

      Tech Tips

      Check the orientation of the inner No. 2 shift lever.

  24. REMOVE FRONT INNER SHIFT LEVER


    1. A005I08

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

      Tech Tips

      Check the orientation of the front inner shift lever.

  25. REMOVE INNER NO. 1 SHIFT LEVER


    1. A005JLS

      Using a pin punch (5 mm) and a hammer, remove the slotted spring pin and inner No. 1 shift lever.

      Tech Tips

      Check the orientation of the inner No. 1 lever.

  26. REMOVE INNER SELECT LEVER


    1. A005K7L

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

      Tech Tips

      Check the orientation of the inner select lever.

  27. SEPARATE SHIFT AND SELECT LEVER SHAFT HEAD


    1. A005L3Q

      Using a pin punch (5 mm) and a hammer, remove the slotted spring pin and the shift and select lever shaft head.

      Tech Tips

      Check the orientation of the shift and select lever shaft head.

  28. REMOVE SHIFT AND SELECT LEVER SHAFT


    1. Remove the shift and select lever shaft from the shift and select lever shaft head.

  29. REMOVE SHIFT INTER LOCK PLATE


    1. A005HF5

      Remove the shift inter lock plate.

  30. REMOVE INPUT SHAFT ASSEMBLY


    1. A005KRW

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

  31. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A005GMH

      Remove the differential case assembly from the front transaxle case.

  32. 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. A005IQ7E13
      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 )

  33. 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. A005K5TE10
      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 )

  34. REMOVE TRANSMISSION MAGNET


    1. A005GOT

      Remove the transmission magnet from the front transaxle case.

  35. REMOVE TRANSMISSION OIL SEPARATOR


    1. A005JK8

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

  36. REMOVE BREATHER PLUG


    1. A005KBM

      Remove the breather plug from the front transaxle case.

  37. 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.

  38. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A005JU6E05

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

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

  39. REMOVE STRAIGHT PIN


    1. A005K9J

      Remove the 5 straight pins from the front transaxle case.

  40. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A005KAU

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

  41. REMOVE INPUT SHAFT COVER


    1. A005GS8

      Remove the input shaft cover from the manual transmission case.

  42. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A005HNY

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

  43. REMOVE TRANSMISSION OIL SEPARATOR


    1. A005KV8

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

  44. 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.

  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. A005GXUE04

      Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.

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

  47. REMOVE TRANSMISSION CASE GASKET


    1. A005K44E02

      Using SST and a hammer, remove the transmission case gasket from the manual transmission case.

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

  48. 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 )