MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

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  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  3. REMOVE RELEASE FORK SUPPORT

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  4. REMOVE CLUTCH RELEASE FORK BOOT

    1. C113599

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

  5. REMOVE CONTROL CABLE BRACKET

    1. C115444

      Remove the 3 bolts and cable bracket from the manual transaxle assembly.

  6. REMOVE FLOOR SHIFT SELECTING BELL CRANK ASSEMBLY

    1. C112480

      Remove the 2 bolts and floor shift selecting bell crank assembly from the manual transaxle assembly.

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C112471N03

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

      09817-16011

  8. REMOVE NO. 1 TRANSMISSION CASE PLUG

    1. C278088

      Using a T55 ''TORX'' socket wrench, remove the No. 1 transmission case plug.

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C116559

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

  10. REMOVE NO. 2 LOCK BALL ASSEMBLY

    1. C116599

      Remove the No. 2 lock ball assembly from the manual transmission case.

  11. REMOVE SHIFT GATE PIN

    1. C116598

      Remove the shift gate pin from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER ASSEMBLY

    1. C112484

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

  13. REMOVE SHIFT AND SELECT LEVER SHAFT STRAIGHT PIN

    1. C277747N01

      While pressing in the shift and select lever shaft straight pin (A) as far as it will go, pull out the shift and select lever shaft straight pin (B) to remove it.

    2. Remove the spring.

  14. REMOVE O-RING

    1. C277749

      Remove the O-ring from the shift and select lever shaft straight pin (B).

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C113635

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

  16. REMOVE DRAIN PLUG

    1. C113634

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

  17. REMOVE SHIFT DETENT BALL

    1. C113593

      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 No. 1 shift detent ball spring seats, 4 shift detent ball compression springs and 4 shift detent balls.

  18. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C116545

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

  19. REMOVE MANUAL TRANSMISSION CASE PLUG

    1. C277754

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

  20. REMOVE MANUAL TRANSMISSION CASE

    1. C113600

      Remove the 6 bolts from the front transaxle case.

    2. C113610

      Remove the 12 bolts from the manual transmission case.

    3. C116542

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

  21. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C113590

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

      Note:

      Do not damage the No. 1 oil receiver pipe.

  22. REMOVE TRANSMISSION OIL SEPARATOR

    1. C277755

      for Manual Transmission Case Side:

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

  23. REMOVE 1ST AND 2ND SHIFT FORK SHAFT

    1. C115434

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

    2. C116327

      Remove the 1st and 2nd shift fork shaft.

  24. REMOVE 3RD AND 4TH SHIFT FORK SHAFT

    1. C117839

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

    2. C117840

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

    3. C115438C04

      *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.

  25. REMOVE NO. 2 GEAR SHIFT FORK

    1. C115439

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

  26. REMOVE NO. 5 GEAR SHIFT FORK SHAFT

    1. C115440

      Using a screwdriver, remove the E-ring from the pin.

    2. C115441

      Remove the pin from the shift arm.

    3. C115442

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

    4. C113585

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

    5. Remove the No. 3 gear shift head from the No. 5 gear shift fork shaft.

  27. REMOVE NO. 1 GEAR SHIFT FORK

    1. C115443

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

  28. REMOVE SHIFT ARM

    1. C116744

      Remove the shift arm from the front transaxle case.

  29. REMOVE REVERSE SHIFT FORK SHAFT

    1. C115428

      Remove the bolt from the reverse shift fork.

    2. C115429

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

  30. REMOVE 5TH AND 6TH SHIFT FORK SHAFT

    1. C115430

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

    2. C115431

      Remove the 5th and 6th shift fork shaft from the front transaxle case.

  31. REMOVE NO. 3 GEAR SHIFT FORK

    1. C277715

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

  32. REMOVE REVERSE SHIFT FORK

    1. C115432

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

  33. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

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  34. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

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  35. REMOVE REVERSE IDLER GEAR

    1. C278117

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

    2. C277716

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

  36. REMOVE INPUT SHAFT, NO. 1 OUTPUT SHAFT ASSEMBLY AND NO. 2 OUTPUT SHAFT ASSEMBLY

    1. C116196

      Remove the 3 shafts at the same time.

      Note:

      Do not drop the input shaft, No. 1 output shaft assembly and No. 2 output shaft assembly.

  37. REMOVE TRANSMISSION OIL SEPARATOR

    1. C277758

      for Front Transaxle Case Side:

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

  38. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY

    1. C115412

      Remove the front differential case assembly from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET

    1. C115449

      Remove the transmission magnet from the front transaxle case.

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

    1. C277774C01

      *a

      Turn

      *b

      Hold

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

      09387-00041

      09387-02020

  41. REMOVE REAR OUTPUT SHAFT BEARING SHIM

    1. C116565

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

  42. REMOVE SHIFT FORK SHAFT BEARING

    1. C113594N01

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

      09387-00041

      09387-01021

      09387-01030

      09527-20011

      09612-65014

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

    1. C113581N02

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

      09387-00041

      09387-01021

      09387-01030

      09612-65014

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

    1. C116544

      Using a snap ring expander, remove the rear input and output shaft bearing shaft snap rings.

  45. REMOVE FRONT INPUT SHAFT BEARING

    1. C278098

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. C277775C01

      *a

      Turn

      *b

      Hold

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

      09612-30012

  46. REMOVE TRANSAXLE CASE OIL SEAL

    1. C279708C01

      *a

      Protective Tape

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

      Note:

      Do not damage the installation surface of the front transmission case.

      Tip:

      Tape the screwdriver tip before use.

  47. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C278099

      Remove the bolt and bearing lock plate from the front transaxle case.

    2. C279717C01

      *a

      Turn

      *b

      Hold

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

      09612-65014

      09612-01020

  48. REMOVE OUTPUT SHAFT COVER

    1. C115453

      Remove the output shaft cover from the front transaxle case.

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

    1. C277777C01

      *a

      Turn

      *b

      Hold

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

      09387-00041

      09387-02020

  50. REMOVE OUTPUT SHAFT COVER

    1. C115454

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE MANUAL TRANSMISSION CASE STRAIGHT PIN

    1. C278092

      Remove the 4 manual transmission case straight pin.

  52. REMOVE SHIFT FORK SHAFT BEARING

    1. C113595N02

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

      09387-00041

      09387-01021

      09612-65014

  53. REMOVE TRANSMISSION CASE OIL SEAL

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  54. REMOVE FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING

    1. C116548

      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.

  55. REMOVE TRANSAXLE CASE OIL SEAL

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  56. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C326346N02

      Using SST, remove the front differential case frontbearing outer race from the front transaxle case.

      09950-40011

      09951-04010

      09953-04030

      09954-04010

      09955-04041

      09957-04010

      09950-60010

      09951-00600