MANUAL TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A01ITWD

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A01IPA5

      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. A01IQ70

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

  4. REMOVE MANUAL TRANSMISSION CASE PLUG


    1. A01IQ57

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

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A01ISGA

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

  6. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A01ITC3

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

  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 RELEASE BLEEDER SUB-ASSEMBLY

    A01INUU

    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. A01IU6K

      Remove the clutch tube boot from the manual transaxle assembly.

    2. A01IU7F

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

    3. A01IN29

      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. A01IODJ

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE TRANSMISSION CASE PLUG


    1. A01IR1Z

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

  13. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A01INIQ

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

  14. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A01IUM5

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

  15. REMOVE LOCK BALL PIN


    1. A01IQP2

      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.

  16. REMOVE SHIFT DETENT BALL


    1. A01IN0B

      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. A01IR0R

      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.

  17. REMOVE OUTER SHIFT LEVER E RING


    1. A01ISX6

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

  18. REMOVE MANUAL TRANSMISSION CASE


    1. A01IUH2

      Remove the 16 bolts.

    2. A01IOPHE01
      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. A01IOE9E01
      Text in Illustration
      *1 Boss

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

    4. A01IP3L

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

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01IPL1

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01IQQO

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

  21. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01IN13

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01IR9E

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

    2. A01ISVG

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

  23. REMOVE OUTER SELECT LEVER


    1. A01IU4NE01
      Text in Illustration
      *1 Mark

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

  24. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A01IPPPE01
      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.

  25. REMOVE INPUT SHAFT ASSEMBLY


    1. A01IPVQ

      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.

  26. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01IRG2

      Remove the differential case assembly from the front transaxle case.

  27. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01IQY5E01

      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. A01INDQE04
      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 )

  28. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01ITKBE01

      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. A01INQIE02
      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 )

  29. REMOVE TRANSMISSION MAGNET


    1. A01IN1W

      Remove the transmission magnet from the front transaxle case.

  30. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01INWK

      for Front Transaxle Case Side:

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

  31. REMOVE BREATHER PLUG


    1. A01IO99

      Remove the breather plug from the front transaxle case.

  32. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A01IRJME01

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

      SST
      09308-00010
    2. A01IN5A

      Remove the output shaft cover from the front transaxle case.

  33. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01IQBCE01

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

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

  34. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A01ITP2

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

  35. REMOVE STRAIGHT PIN


    1. A01ITZ3

      Remove the 5 straight pins from the front transaxle case.

  36. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A01IQKI

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

  37. REMOVE INPUT SHAFT COVER


    1. A01IT4LE01

      Remove the input shaft cover from the manual transmission case.

  38. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A01IR1O

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

  39. REMOVE TRANSMISSION OIL SEPARATOR


    1. A01IRO0

      For manual transmission case side:

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

  40. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A01IUPF

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

  41. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A01IT4F

      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.

  42. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A01IPJJE02
      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.

  43. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01INJNE01

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

      SST
      09308-00010

  44. REMOVE TRANSMISSION CASE OIL SEAL


    1. A01IUIGE01

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

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

  45. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A01IRO3E01

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

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