MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A01IONS

      Remove the clutch release fork with the clutch release bearing from the manual transaxle assembly.

  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. A01IO1Z

      Remove the clutch release bearing and clip from the clutch release fork.

  3. REMOVE RELEASE FORK SUPPORT


    1. A01IO0U

      Remove the release fork support from the manual transaxle assembly.

      Tech Tips

      If there is adhesive on the threaded portion of the release fork support, replace a release fork support and clean the threaded potion of the housing.

  4. REMOVE CLUTCH RELEASE FORK BOOT


    1. A01ITAN

      Remove the clutch release fork boot from the front transaxle case.

  5. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A01IOP2

      Remove the 3 bolts and support bracket from the manual transaxle.

  6. REMOVE SELECTING BELL CRANK ASSEMBLY


    1. A01ITF6

      Remove the 2 bolts and selecting bell crank from the manual transmission case.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01ISJKE02

      Using SST, remove the back-up light switch and gasket.

      SST
      09816-30010

  8. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01IURB

      Remove the lock ball from the manual transmission case.

  9. REMOVE NO. 2 LOCK BALL ASSEMBLY


    1. A01IUA7

      Remove the lock ball from the manual transmission case.

  10. REMOVE SHIFT GATE PIN


    1. A01IN8I

      Remove the shift gate pin from the manual transmission case.

  11. REMOVE SHIFT AND SELECT LEVER ASSEMBLY


    1. A01INE6

      Remove the 4 bolts and shift and select lever assembly from the manual transmission case.

  12. REMOVE SHIFT AND SELECT PIN


    1. A01IOXP

      While pressing in the shift and select pin as far as it will go, pull out the shift and select pin to remove it.

    2. Remove the spring.

  13. REMOVE O-RING


    1. A01INFYE01

      Remove the O-ring from the shift and select pin.

  14. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01IOU0

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

  15. REMOVE DRAIN PLUG


    1. A01ING6

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

  16. REMOVE BALL


    1. A01IT2E

      Using a 6 mm hexagon wrench, remove the 4 detent ball plugs from the front transaxle case.

    2. Using a magnet hand, remove the 4 spring seats, 4 springs and 4 balls.

  17. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01IO7U

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

  18. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A01IST3E01

      Remove the 2 manual transmission case plugs from the manual transmission case.

  19. REMOVE MANUAL TRANSMISSION CASE


    1. A01IU6U

      Remove the 6 bolts from the front transaxle case side.

    2. A01IP8B

      Remove the 12 bolts from the manual transmission case side.

    3. A01ITRG

      Using 2 pairs of snap ring pliers to keep the snap ring stretched, remove the manual transmission case.

  20. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01ISSA

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

      Note

      Do not damage the No. 1 oil receiver pipe.

  21. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01IU9OE01

      for Manual Transmission Case Side:

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

  22. REMOVE 1ST AND 2ND SHIFT FORK SHAFT


    1. A01ITVF

      Remove the bolt from the No. 1 gear shift fork.

    2. A01IQIM

      Remove the 1st and 2nd shift fork shaft.

  23. REMOVE 3RD AND 4TH SHIFT FORK SHAFT


    1. A01ISUB

      Using a 5 mm pin punch and hammer, tap out the pin from the No. 2 gear shift head.

    2. A01ITQH

      Using a 5 mm pin punch and hammer, tap out the pin from the No. 2 gear shift fork.

    3. A01IP6ME03
      Text in Illustration
      *1 3rd and 4th Shift Fork Shaft
      *2 No. 2 Gear Shift Head

      Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head.

  24. REMOVE NO. 2 GEAR SHIFT FORK


    1. A01IUOL

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

  25. REMOVE NO. 5 GEAR SHIFT FORK SHAFT


    1. A01IQR2

      Using a screwdriver, remove the E-ring from the front transaxle case.

    2. A01IQRF

      Remove the pin from the front transaxle case.

    3. A01ISI5

      Remove the No. 5 gear shift fork shaft from the front transaxle case.

    4. A01IN7B

      Using a 5 mm pin punch and hammer, tap out the pin.

    5. Remove the No. 3 gear shift head.

  26. REMOVE NO. 1 GEAR SHIFT FORK


    1. A01IOKF

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

  27. REMOVE SHIFT ARM


    1. A01IO2R

      Remove the shift arm from the front transaxle case.

  28. REMOVE REVERSE SHIFT FORK SHAFT


    1. A01IQVZ

      Remove the bolt from the reverse shift fork.

    2. A01IQG1

      Remove the reverse shift fork shaft.

  29. REMOVE 5TH AND 6TH SHIFT FORK SHAFT


    1. A01IPVX

      Remove the bolt from the No. 3 gear shift fork.

    2. A01IP6X

      Remove the 5th and 6th shift fork shaft.

  30. REMOVE NO. 3 GEAR SHIFT FORK


    1. A01IO0Z

      Remove the No. 3 gear shift fork from the No. 2 output shaft assembly.

  31. REMOVE REVERSE SHIFT FORK


    1. A01ISIZ

      Remove the reverse shift fork from the No. 2 output shaft assembly.

  32. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE


    1. A01IRKV

      Using a feeler gauge, measure the reverse idler gear thrust clearance.

      Standard clearance
      0.40 to 1.05 mm (0.00158 to 0.0413 in.)
      Maximum clearance
      1.05 mm (0.0413 in.)

      If the clearance is more than the maximum, replace the reverse idler gear, needle roller bearing and reverse idler gear shaft.

  33. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A01ITNS

      Using a dial indicator, measure the reverse idler gear radial clearance.

      Standard clearance
      0.015 to 0.048 mm (0.000591 to 0.00188 in.)
      Maximum clearance
      0.048 mm (0.00188 in.)

      If the clearance is more than the maximum, replace the reverse idler gear, needle roller bearing and reverse idler gear shaft.

  34. REMOVE REVERSE IDLER GEAR


    1. A01IU61E01

      Remove the reverse idler gear shaft by sliding and lifting it.

    2. A01IOTU

      Remove the reverse idler gear, needle roller bearing and reverse idler thrust washer from the reverse idler gear shaft.

  35. REMOVE INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT


    1. A01IQSF

      Remove the 3 shafts at the same time.

  36. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01IR2UE02

      for Front Transaxle Case Side:

      Remove the 2 bolts and transmission oil separator from the front transaxle case.

  37. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A01IUIK

      Remove the differential case from the front transaxle case.

  38. REMOVE TRANSMISSION MAGNET


    1. A01IRXL

      Remove the transmission magnet from the front transaxle case.

  39. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE


    1. A01IR1AE01

      Using SST, remove the No. 2 output shaft rear bearing outer race the manual transmission case to remove it.

      SST
      09387-00041   ( 09387-02020 )

  40. REMOVE OUTPUT SHAFT REAR BEARING SHIM


    1. A01IP43

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

  41. REMOVE SHIFT FORK SHAFT BEARING


    1. A01ITARE01

      Using SST, remove the 4 shift fork shaft bearings from the manual transmission case to remove them.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )
      09527-20011

  42. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A01IQOPE01

      Using SST, remove the shift and select lever shaft needle roller bearing from the manual transmission case to remove it.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )

  43. REMOVE INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A01ITLC

      Using snap ring expander, remove the 2 snap rings.

  44. REMOVE INPUT SHAFT FRONT BEARING


    1. A01IR90

      Remove the bolt from the front transaxle case.

    2. A01IPB3E01

      Using SST, remove the input shaft bearing from the front transaxle case to remove it.

      SST
      09612-30012

  45. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01ISBB

      Using a screwdriver, remove the front transaxle case oil seal from the front transaxle case.

  46. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01IQ23

      Remove the bolt from the front transaxle case.

    2. A01IR19E01

      Using SST, remove the output shaft front bearing from the front transaxle case to remove it.

      SST
      09612-65014   ( 09612-01020 )

  47. REMOVE OUTPUT SHAFT COVER


    1. A01IU7P

      Remove the output shaft cover from the front transaxle case.

  48. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE


    1. A01IN9FE01

      Using SST, remove the No. 2 output shaft front bearing outer race from the front transaxle case to remove it.

      SST
      09387-00041   ( 09387-02020 )

  49. REMOVE OUTPUT SHAFT COVER


    1. A01IPX1

      Remove the output shaft cover from the front transaxle case.

  50. REMOVE SHIFT FORK SHAFT BEARING


    1. A01IRQAE01

      Using SST, remove the 4 shift fork shaft bearings from the front transaxle case to remove them.

      SST
      09612-65014
      09387-00041   ( 09387-01021 )

  51. REMOVE TRANSAXLE CASE OIL SEAL LH


    1. A01IQVC

      Using a screwdriver, remove the transaxle case oil seal LH from the manual transmission case.

      Tech Tips

      Tape the screwdriver tip before use.

  52. REMOVE FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A01ITN2

      Using a brass bar and hammer, tap out the front differential case rear outer race bearing and front differential case rear shim from the manual transmission case.

  53. REMOVE TRANSAXLE CASE OIL SEAL RH


    1. A01ITPE

      Using a screwdriver, remove the transaxle case oil seal RH from the front transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

  54. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01IRXNE01

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

      SST
      09950-40011   ( 09951-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010 )
      09950-60010   ( 09951-00600 )