MANUAL TRANSAXLE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

When replacing any tapered roller bearing outer race, replace both the tapered roller bearing and tapered roller bearing outer race with new ones.

PROCEDURE

  1. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  2. REMOVE CLUTCH RELEASE FORK LEVER

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  3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

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  4. REMOVE NO. 1 CLUTCH HOUSING COVER

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  5. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET

    1. F100309

      Remove the 2 bolts and floor shift control lever housing support bracket from the front transaxle case.

  6. REMOVE MANUAL TRANSAXLE CASE PLUG

    1. F100310

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

  7. REMOVE MANUAL TRANSAXLE DRAIN PLUG

    1. C304367

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

  8. REMOVE MANUAL TRANSAXLE FILLER PLUG

    1. C304365

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

  9. REMOVE NEUTRAL POSITION SWITCH

    1. C303551

      Using SST, remove the neutral position switch and gasket from the manual transaxle assembly.

      09817-16011

  10. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C303238

      Disengage the 2 clamps to disconnect the back-up light switch wire harness from the manual transaxle assembly.

    2. C112765N01

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

      09817-16011

  11. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C306098

      Using a 18 mm socket wrench, remove the No. 1 lock ball assembly from the manual transmission case.

  12. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. F100317C02

      *a

      Wire Harness Clamp

      Remove the 4 bolts, 2 wire harness clamps and shift and select lever shaft assembly from the manual transmission case.

    2. Remove the select return compression spring from the manual transmission case.

  13. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. F100318

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

  14. REMOVE MANUAL TRANSMISSION CASE

    1. F100320

      Remove the 5 bolts from the front transaxle case side.

    2. F100319

      Remove the 8 bolts from the manual transmission case side.

    3. Using a plastic hammer, remove the manual transmission case from the front transaxle case.

  15. REMOVE REVERSE IDLER GEAR SHAFT

    1. G020851

      Remove the reverse idler gear shaft from the front transaxle case.

  16. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C303228

      Remove the reverse idler gear sub-assembly from the front transaxle case.

  17. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. G020852

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

  18. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

    1. G020853

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

    2. G020854

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

    3. G020855

      Remove the No. 1 gear shift fork shaft, No. 1 gear shift head and No. 1 gear shift fork from the front transaxle case.

    4. G020856

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 1 gear shift fork shaft.

      Tip:

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

  19. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    1. C303209

      Using a Magnet Hand, remove the straight pin from the No. 3 gear shift fork.

    2. G020858

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

    3. G020859

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Tip:

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

    4. G020860C01

      *1

      No. 3 Gear Shift Fork Shaft

      *2

      Compression Spring

      *3

      No. 3 Gear Shift Head

      *4

      No. 3 Gear Shift Fork

      Remove the No. 3 gear shift fork shaft, compression spring, No. 3 gear shift head and No. 3 gear shift fork from the front transaxle case.

    5. G020861

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Tip:

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

  20. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    1. D005727

      Using a Magnet Hand, remove the straight pin from the reverse shift fork.

    2. G020862

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Tip:

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

    3. G020913

      Remove the bolt from the No. 2 gear shift fork.

    4. G020914

      Shift the No. 2 transmission hub sleeve to the 4th gear position.

    5. C303232C01

      *1

      No. 2 Gear Shift Fork Shaft

      *2

      No. 2 Gear Shift Fork

      *3

      Reverse Shift Fork

      Remove the No. 2 gear shift fork shaft, No. 2 gear shift fork and reverse shift fork from the front transaxle case.

    6. G020915

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Tip:

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

  21. REMOVE INPUT SHAFT ASSEMBLY

    1. G020916

      Remove the input shaft assembly from the front transaxle case.

  22. REMOVE OUTPUT SHAFT ASSEMBLY

    1. Remove the output shaft assembly from the front transaxle case.

  23. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. G021163

      Remove the differential case assembly from the front transaxle case.

  24. REMOVE TRANSMISSION MAGNET

    1. G021178

      Remove the transmission magnet from the front transaxle case.

  25. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. G020921C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the installation surfaces of the front transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  26. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)

    1. G020922N03

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

      09308-00010

      Note:

      Do not damage or deform the front output shaft bearing (outer race) (when reusing the front output shaft bearing (outer race)).

  27. REMOVE OUTPUT SHAFT COVER

    1. G020987

      Remove the output shaft cover from the front transaxle case.

  28. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)

    1. C230554N02

      Using SST, remove the front differential case front tapered roller bearing (outer race) from the front transaxle case.

      09308-00010

      Note:

      Do not damage or deform the front differential case front tapered roller bearing (outer race) (when reusing the front differential case front tapered roller bearing (outer race)).

  29. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

    1. C230553N02

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

      09308-00010

      Note:

      Be careful not to damage the installation surfaces of the front transaxle case.

  30. REMOVE NO. 2 OIL RECEIVER PIPE

    1. C230550

      Remove the No. 2 oil receiver pipe from the manual transmission case.

  31. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. G020992

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

  32. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)

    1. C303210C01

      *a

      Turn

      *b

      Hold

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

      09527-30010

      09612-65014

      09612-01030

      09612-01050

      Note:

      Do not damage or deform the rear output shaft bearing (outer race) (when reusing the rear output shaft bearing (outer race)).

  33. REMOVE REAR OUTPUT SHAFT BEARING SHIM

    1. G020994

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

  34. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

    1. C230551N02

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

      09308-00010

      Note:

      Be careful not to damage the installation surfaces of the manual transmission case.

  35. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)

    1. G020989N03

      Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and differential case shim from the manual transmission case.

      09950-60010

      09951-00620

      09950-70010

      09951-07200

      Note:

      Do not damage or deform the front differential case rear tapered roller bearing (outer race) (when reusing the front differential case rear tapered roller bearing (outer race)).