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

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  5. REMOVE CONTROL CABLE BRACKET

    1. C300489

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

  6. REMOVE SELECTING BELL CRANK ASSEMBLY

    1. C300490

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

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  8. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C116559

      Remove the lock ball from the manual transmission case.

  9. REMOVE NEUTRAL POSITION SWITCH (w/ Stop And Start System)

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  10. REMOVE NO. 2 LOCK BALL ASSEMBLY

    1. C116599

      Remove the lock ball 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. C301105

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

  13. REMOVE SHIFT AND SELECT PIN

    1. C117499

      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.

  14. REMOVE O-RING

    1. C363547

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

  15. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C113635

      Remove the 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 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 spring seats, 4 springs and 4 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. C363549

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

  20. REMOVE MANUAL TRANSMISSION CASE

    1. C327698

      Remove the 6 bolts from the front transaxle case side.

    2. C327697

      Remove the 12 bolts from the manual transmission case side.

    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. C363551

      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. C115438E03

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

      Table 1. Text in Illustration

      *1

      3rd and 4th Shift Fork Shaft

      *2

      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.

  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.

  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.

  31. REMOVE NO. 3 GEAR SHIFT FORK

    1. C363554

      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. C363555

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

    2. C363556

      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 AND NO. 2 OUTPUT SHAFT

    1. C116196

      Remove the 3 shafts at the same time.

  37. REMOVE TRANSMISSION OIL SEPARATOR

    1. C363557

      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 differential case from the front transaxle case.

  39. REMOVE TRANSMISSION MAGNET

    1. C115449

      Remove the transmission magnet from the front transaxle case.

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

    1. C113586E01

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

      09387-00041

      09387-02020

  41. REMOVE OUTPUT SHAFT REAR BEARING SHIM

    1. C116565

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

  42. REMOVE SHIFT FORK SHAFT BEARING

    1. C113594E03

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

      09612-65014

      09387-00041

      09387-01021

      09527-20011

  43. REMOVE SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

    1. C113581E01

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

      09612-65014

      09387-00041

      09387-01021

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

    1. C116544

      Using snap ring expander, remove the 2 snap rings.

  45. REMOVE INPUT SHAFT FRONT BEARING

    1. C113584

      Remove the bolt from the front transaxle case.

    2. C113580E01

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

      09612-30012

  46. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C116577

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

  47. REMOVE OUTPUT SHAFT FRONT BEARING

    1. C113583

      Remove the bolt from the front transaxle case.

    2. C113597E03

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

      09612-65014

      09612-01020

  48. REMOVE OUTPUT SHAFT COVER

    1. C300491

      Remove the output shaft cover from the front transaxle case.

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

    1. C113587E03

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

      09387-00041

      09387-02020

  50. REMOVE OUTPUT SHAFT COVER

    1. C300492

      Remove the output shaft cover from the front transaxle case.

  51. REMOVE SHIFT FORK SHAFT BEARING

    1. C113595E03

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

      09612-65014

      09387-00041

      09387-01021

  52. REMOVE TRANSAXLE CASE OIL SEAL LH

    1. C116195

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

      Tip:

      Tape the screwdriver tip before use.

  53. REMOVE FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE

    1. C116548

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

  54. REMOVE TRANSAXLE CASE OIL SEAL RH

    1. C116194

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

      Tip:

      Tape the screwdriver tip before use.

  55. REMOVE FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE

    1. C326346E02

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

      09950-40011

      09951-04010

      09953-04030

      09954-04010

      09955-04041

      09957-04010

      09950-60010

      09951-00600