MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A001Y89

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A001SQX

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

  3. REMOVE TRANSMISSION REVOLUTION SENSOR


    1. A001TTE

      Remove the bolt, transmission revolution sensor and spacer from the manual transmission case.

      Note

      If the O-ring is damaged, replace the transmission revolution sensor with a new one.

  4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A001SJE

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

  5. REMOVE NEUTRAL POSITION SWITCH


    1. A001XB0

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

  6. REMOVE CONTROL CABLE BRACKET ASSEMBLY


    1. A001VPC

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

  7. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A001XY2

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

  8. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A001VVZ

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

  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 RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  12. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  13. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    Click here

  14. SECURE MANUAL TRANSAXLE ASSEMBLY


    1. A001T0OC07
      *a Wooden Block

      Place the manual transaxle assembly on wooden blocks.

  15. REMOVE TRANSMISSION CASE PLUG


    1. A001UAQ

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

  16. REMOVE NO. 1 LOCK BALL ASSEMBLY


    1. A001UJ7

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

  17. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    1. A001X1X

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

  18. REMOVE LOCK BALL PIN


    1. A001XS3

      Using a 10 mm hexagon socket wrench, 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.

  19. REMOVE SHIFT DETENT BALL


    1. A001XMH

      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 shift detent ball compression spring and shift detent ball from the manual transmission case.

    3. A001TX8

      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 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.

  20. REMOVE OUTER SHIFT LEVER E-RING


    1. A001WU6

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

  21. REMOVE MANUAL TRANSMISSION CASE


    1. A001V95

      Remove the 16 bolts.

    2. A001TT7C06
      *a 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. A001V5ZC01
      *a Boss

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

    4. A001SFR

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

  22. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A001VOW

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

  23. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A001W62

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

  24. REMOVE REVERSE SHIFT FORK


    1. Secure the No. 4 gear shift fork shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A001VSW

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the reverse shift fork.

    3. A001SQ1

      Remove the reverse shift fork from the No. 4 gear shift fork shaft.

  25. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A001X0K

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

  26. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A001UKZ

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

    2. A001SQIC01
      *1 Shift and Select Lever Shaft Assembly
      *2 Shift Inter Lock Plate

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

    3. Remove the shift inter lock plate from the front transaxle case.

  27. REMOVE OUTER SELECT LEVER


    1. A001WMLC04
      *a Mark

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

  28. REMOVE OUTER SELECT LEVER OIL SEAL


    1. A001U5OC04
      *a 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.

  29. REMOVE INPUT SHAFT ASSEMBLY


    1. A001V0Z

      Remove the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly from the front transaxle case.

  30. REMOVE NO. 1 GEAR SHIFT HEAD


    1. Secure the No. 1 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A001SQG

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 1 gear shift head.

    3. A001VJR

      Remove the No. 1 gear shift head from the No. 1 gear shift fork assembly.

  31. REMOVE NO. 2 GEAR SHIFT HEAD


    1. Secure the No. 2 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A001SW0

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 2 gear shift head.

    3. A001WXF

      Remove the No. 2 gear shift head from the No. 2 gear shift fork assembly.

  32. REMOVE NO. 2 REVERSE PRE-BALK HEAD


    1. A001SS5C01
      *1 Snap Ring
      *a Protective Tape

      Using 2 screwdrivers with their tips wrapped with protective tape and a hammer, remove the snap ring from the No. 2 gear shift fork assembly.

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

    2. A001TOO

      Remove the spacer from the No. 2 gear shift fork assembly.

    3. A001SRK

      Remove the No. 2 reverse pre-balk head from the No. 2 gear shift fork assembly.

    4. Secure the No. 2 reverse pre-balk head in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    5. A001U42

      Using a 3 mm pin punch and a hammer, remove the straight pin from the No. 2 reverse pre-balk head.

    6. A001X4FC02
      *1 Bimetal Formed Bushing
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape and a hammer, remove the 2 bimetal formed bushings from the No. 2 reverse pre-balk head.

      Note

      Do not damage the No. 2 reverse pre-balk head.

  33. REMOVE SHIFT LEVER STOPPER


    1. A001SHM

      Remove the torsion spring from the No. 2 gear shift fork assembly.

    2. A001T62

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the shift lever stopper.

    3. A001WCB

      Remove the shift lever stopper from the No. 2 gear shift fork assembly.

  34. REMOVE NO. 3 GEAR SHIFT HEAD


    1. Secure the No. 3 gear shift fork assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A001SJY

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 gear shift head.

    3. A001TBS

      Remove the No. 3 gear shift head from the No. 3 gear shift fork assembly.

  35. REMOVE NO. 3 REVERSE PRE-BALK HEAD


    1. A001U0L

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 reverse pre-balk head.

    2. A001Y8U

      Remove the No. 3 reverse pre-balk head from the No. 3 gear shift fork assembly.

  36. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A001SGP

      Remove the differential case assembly from the front transaxle case.

  37. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A001Y77N03

      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. A001U1KC04
      *a Hold
      *b Turn

      Using SST, remove the front differential case front tapered roller bearing (inner race) 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 )

  38. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A001V75N03

      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. A001Y8BC04
      *a Hold
      *b Turn

      Using SST, remove the front differential case rear tapered roller bearing (inner race) 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 )

  39. REMOVE TRANSMISSION MAGNET


    1. A001WRW

      Remove the transmission magnet from the front transaxle case.

  40. REMOVE TRANSMISSION OIL SEPARATOR


    1. A001XQT

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

  41. REMOVE BREATHER PLUG


    1. A001VKZ

      Remove the breather plug from the front transaxle case.

  42. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)


    1. A001Y4DN03

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

      SST
      09308-00010
    2. A001Y0G

      Remove the output shaft cover from the front transaxle case.

  43. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    1. A001VQQN03

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

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

  44. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    1. A001UVR

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

  45. REMOVE STRAIGHT PIN


    1. A001VBJ

      Remove the 5 straight pins from the front transaxle case.

  46. REMOVE REAR INPUT SHAFT BEARING SHIM


    1. A001XIK

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

  47. REMOVE INPUT SHAFT COVER


    1. A001XDS

      Remove the input shaft cover from the manual transmission case.

  48. REMOVE NO. 1 OIL RECEIVER PIPE


    1. A001WIT

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

  49. REMOVE TRANSMISSION OIL SEPARATOR


    1. A001TSF

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

  50. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A001U84

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

  51. REMOVE OUTER NO. 1 SHIFT LEVER


    1. A001X2S

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

      Tech Tips

      When removing the inner shift lever slotted spring pin, align the inner shift lever slotted spring 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.

  52. REMOVE OUTER SHIFT LEVER OIL SEAL


    1. A001V38C04
      *a 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.

  53. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)


    1. A001X4XN06

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

      SST
      09308-00010

  54. REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. A001TCXN03

      Using SST and a hammer, remove the front drive shaft oil seal LH from the manual transmission case.

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

  55. REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. A001U64N03

      Using SST and a hammer, remove the front drive shaft oil seal RH from the front transaxle case.

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