MULTI-MODE MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C198758

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG

    1. C198759

      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. C198760C04

      *a

      27 mm Deep Socket Wrench

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

  4. REMOVE TRANSMISSION REVOLUTION SENSOR

    1. C198761

      Remove the bolt and transmission revolution sensor.

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

  5. REMOVE NEUTRAL POSITION SWITCH

    1. A295388C02

      *a

      27 mm Deep Socket Wrench

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

  6. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY

    1. C277513

      Remove the 6 bolts and wire harness clamp bracket.

    2. C202647C02

      *a

      Protective Tape

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

    3. C275945

      Remove the 2 ring pins from the shift and select actuator assembly.

    4. C276339

      Remove the bolt and breather protector from the shift and select actuator assembly.

    5. C276340

      Remove the breather plug cap from the shift and select actuator assembly.

  7. REMOVE NO. 1 CLUTCH HOUSING COVER

    1. Remove the No. 1 clutch housing cover from the multi-mode manual transaxle assembly.

  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 RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  12. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  13. SECURE MANUAL TRANSAXLE ASSEMBLY

    1. C198765C02

      *a

      Wooden Block

      Place the manual transaxle assembly on wooden blocks.

  14. REMOVE TRANSMISSION CASE PLUG

    1. C198766

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

  15. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C202643

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

  16. REMOVE SHIFT DETENT BALL

    1. C198767

      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. C198768

      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.

  17. REMOVE MANUAL TRANSMISSION CASE

    1. C198771

      Remove the 16 bolts.

    2. C198773C02

      *a

      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.

  18. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C198775

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

  19. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. C198776

      Turn the reverse shift fork shaft assembly clockwise.

    2. C198777

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

  20. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. C198778

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

  21. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. C198779

      Turn the shift and select lever shaft assembly clockwise.

    2. C198781

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

  22. REMOVE INNER NO. 2 SHIFT LEVER

    1. C198791C02

      *a

      5 mm Pin Punch

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

      Tip:

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

  23. REMOVE FRONT INNER SHIFT LEVER

    1. C198793C02

      *a

      5 mm Pin Punch

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

      Tip:

      Check the orientation of the front inner shift lever.

  24. REMOVE INNER NO. 1 SHIFT LEVER

    1. C198795C02

      *a

      5 mm Pin Punch

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

      Tip:

      Check the orientation of the inner No. 1 shift lever.

  25. REMOVE INNER SELECT LEVER

    1. C198797C02

      *a

      5 mm Pin Punch

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

      Tip:

      Check the orientation of the inner select lever.

  26. REMOVE SHIFT AND SELECT LEVER SHAFT HEAD

    1. C198799C02

      *a

      5 mm Pin Punch

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

      Tip:

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

  27. REMOVE SHIFT AND SELECT LEVER SHAFT

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

  28. REMOVE SHIFT INTER LOCK PLATE

    1. C198783

      Remove the shift inter lock plate.

  29. REMOVE INPUT SHAFT ASSEMBLY

    1. C198784

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

  30. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C195308

      Remove the differential case assembly from the front transaxle case.

  31. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C194639N04

      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.

      09308-00010

    2. C193754C03

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00390

  32. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. C194651E01

      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.

      09308-00010

    2. C193753C03

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00390

  33. REMOVE TRANSMISSION MAGNET

    1. C194634

      Remove the transmission magnet from the front transaxle case.

  34. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194635

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

  35. REMOVE BREATHER PLUG

    1. C195309

      Remove the breather plug from the front transaxle case.

  36. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C194637N04

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

      09308-00010

    2. C194638

      Remove the output shaft cover from the front transaxle case.

  37. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C194641N04

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

      09950-60010

      09951-00360

      09950-70010

      09951-07150

  38. REMOVE STRAIGHT PIN

    1. C195325

      Remove the 5 straight pins from the front transaxle case.

  39. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. C202644

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

  40. REMOVE INPUT SHAFT COVER

    1. C202645

      Remove the input shaft cover from the manual transmission case.

  41. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C277512

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

  42. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194647

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

  43. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY

    1. C202646

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

  44. REMOVE REAR OUTPUT SHAFT BEARING

    1. C194650N05

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

      09308-00010

  45. REMOVE TRANSMISSION CASE OIL SEAL

    1. C194652N04

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

      09950-60010

      09951-00620

      09950-70010

      09951-07150

  46. REMOVE TRANSMISSION CASE GASKET

    1. C198809N01

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

      09950-60010

      09951-00200

      09950-70010

      09951-07100

  47. REMOVE TRANSAXLE CASE OIL SEAL

    1. C201402N04

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

      09950-60010

      09951-00530

      09950-70010

      09951-07150