MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C199064

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG

    1. C199063

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

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C199065

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

  4. REMOVE TRANSMISSION CASE PLUG (w/o Stop and Start System)

    1. C206934

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

  5. REMOVE NEUTRAL POSITION SWITCH (w/ Stop and Start System)

    Click here

  6. REMOVE CONTROL CABLE BRACKET ASSEMBLY

    1. C199067

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

  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

    1. Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG

    1. Remove the release cylinder bleeder plug from the clutch release bleeder sub-assembly.

  9. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  10. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  11. SECURE MANUAL TRANSAXLE ASSEMBLY

    1. C199068

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C199070

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

  13. REMOVE LOCK BALL PIN

    1. C199071

      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.

    3. C199069

      Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.

    4. Using a magnet hand, remove the shift and select lever shaft compression spring and lock ball pin from the manual transmission case.

  14. REMOVE SHIFT DETENT BALL

    1. C199072

      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. C199073

      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.

  15. REMOVE OUTER SHIFT LEVER E-RING

    1. C199074

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

  16. REMOVE MANUAL TRANSMISSION CASE

    1. C199075

      Remove the 17 bolts.

    2. C202174C03

      *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. C202175

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

    4. C202176

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

  17. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C202177

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

  18. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. C202178

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

  19. REMOVE REVERSE SHIFT FORK

    1. C200913

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

    2. Remove the reverse shift fork from the reverse shift fork shaft assembly.

  20. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. C202179

      Using a 6 mm hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.

  21. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. C203070

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

  22. REMOVE OUTER SELECT LEVER

    1. C202180

      Remove the inner select lever bolt.

    2. C203006

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

  23. REMOVE OUTER SELECT LEVER OIL SEAL

    1. C202195C03

      *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.

  24. REMOVE INPUT SHAFT ASSEMBLY

    1. C202181

      Remove the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.

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

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

    4. Remove the No. 2 gear shift fork shaft assembly from the input shaft assembly.

  25. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C202182

      Remove the differential case assembly from the front transaxle case.

  26. REMOVE TRANSMISSION MAGNET

    1. C202185

      Remove the transmission magnet from the front transaxle case.

  27. REMOVE BREATHER PLUG

    1. C202186

      Remove the breather plug from the front transaxle case.

  28. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C202187E01

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

      09308-00010

    2. C202188

      Remove the output shaft cover from the front transaxle case.

  29. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C202189E01

      Using SST, tap out the front transaxle case oil seal from the front transaxle case.

      09950-60010

      09951-00360

      09950-70010

      09951-07150

  30. REMOVE STRAIGHT PIN

    1. C204734

      Remove the 5 straight pins from the front transaxle case.

  31. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. C202191

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

  32. REMOVE INPUT SHAFT COVER

    1. C202192

      Remove the input shaft cover from the manual transmission case.

  33. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C202193

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

  34. REMOVE OUTER NO. 1 SHIFT LEVER

    1. C202879

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

      Tip:

      When removing the inner shaft lever slotted spring pin, align the inner shift lever slotted spring pin with the hole in the 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.

  35. REMOVE OUTER SHIFT LEVER OIL SEAL

    1. C202195C03

      *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.

  36. REMOVE REAR OUTPUT SHAFT BEARING

    1. C202196E01

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

      09308-00010

  37. REMOVE TRANSMISSION CASE OIL SEAL (for LH SIDE)

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  38. REMOVE TRANSAXLE CASE OIL SEAL (for RH SIDE)

    Click here

  39. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C202183E01

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

      09308-00010

    2. C204250C01

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04020

      09952-04010

      09953-04030

      09954-04030

      09955-04031

      09957-04010

      09958-04011

      09950-60010

      09951-00420

      09951-00520

      09952-06010

  40. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. C202184E01

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

      09308-00010

    2. C199077C02

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04021

      09957-04010

      09958-04011

      09950-60010

      09951-00350

      09951-00550

      09952-06010