MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    1. A004HPK

      Remove the manual transmission filler plug and gasket.

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    1. A004KVG

      Remove the manual transmission drain plug and gasket.

  3. REMOVE RELEASE FORK SUPPORT


    1. A004IG8

      Using a 19 mm deep socket wrench, remove the release fork support from the clutch housing.

  4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    1. A004JML

      Disengage the 3 clamps.

    2. A004KQB

      Using a 19 mm union nut wrench, remove the back-up light switch assembly and gasket.

  5. REMOVE NEUTRAL POSITION SWITCH ASSEMBLY


    1. A004JDT

      Disengage the clamp.

    2. A004HFE

      Using a 19 mm union nut wrench, remove the neutral position switch assembly and gasket.

  6. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A004IWW

      Remove the bolt and wire harness clamp bracket.

  7. REMOVE LOCK BALL PIN


    1. A004HU6

      Using a 10 mm hexagon socket wrench, remove the head straight screw plug, compression spring and lock ball pin.

  8. REMOVE HOLDER


    1. A004IRA

      Using a 27 mm deep socket wrench, remove the holder, compression spring and lock ball pin.

  9. REMOVE TRANSMISSION EXTENSION HOUSING SUB-ASSEMBLY


    1. A004JSN

      Remove the bolt.

    2. A004KX9E01
      Text in Illustration
      *1 Clamp

      Remove the 8 bolts and clamp.

    3. A004J0H

      Using a plastic hammer, remove the transmission extension housing sub-assembly.

      Note


      • Be sure to remove the transmission extension housing sub-assembly while the transmission is in neutral.

      • Do not damage the transmission extension housing sub-assembly.

  10. REMOVE EXTENSION HOUSING REAR OIL SEAL


    1. A004JLWE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the extension housing rear oil seal.

      Note

      Do not damage the transmission extension housing sub-assembly.

      Tech Tips

      Remove the transmission extension housing sub-assembly while protecting it with a piece of cloth.

  11. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. A004INE

      Using a plastic hammer, remove the extension housing dust deflector.

  12. REMOVE TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A004IYTE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the transmission extension housing oil seal.

      Note

      Do not damage the transmission extension housing sub-assembly.

      Tech Tips

      Remove the transmission extension housing sub-assembly while protecting it with a piece of cloth.

  13. REMOVE NO. 2 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A004JEX

      Remove the No. 2 extension housing oil receiver pipe.

  14. REMOVE NO. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A004KML

      Remove the bolt, No. 1 extension housing oil receiver pipe and stopper plate.

    2. A004HEJ

      Remove the straight pin.

  15. REMOVE SHIFT SHAFT


    1. A004HQY

      Slide and remove the shift shaft and No. 1 shift inter lock block.

  16. REMOVE NO. 1 SHIFT INTER LOCK BLOCK


    1. A004K2N

      Remove the No. 1 shift inter lock block from the shift shaft.

  17. REMOVE FRONT SHIFT INNER LEVER


    1. A004HY9

      Remove the bolt and front shift inner lever from the shift shaft.

  18. REMOVE HEAD STRAIGHT SCREW PLUG


    1. A004KCL

      Using a T40 "TORX" socket wrench, remove 3 head straight screw plugs.

    2. A004JPF

      Using a magnet hand, remove the 2 compression springs and 2 balls.

  19. REMOVE SHIFT ARM


    1. A004I8J

      Using a screwdriver, remove the E-ring.

      Note

      Use a cloth to prevent the E-ring from flying off.

    2. A004K60

      Remove the shift arm.

  20. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A004JWD

      Remove the No. 3 gear shift fork shaft and 5th shift head together.

      Note


      • Be careful not to drop the ball from the 5th shift head.

      • The ball on the transmission case may fall inside the transmission case. If that happens, take it out when the transmission case is removed.

    2. Remove the ball from the 5th shift head.

    3. A004KXW

      Using a magnetic hand, remove the ball.

  21. REMOVE 5TH SHIFT HEAD


    1. A004ITG

      Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

      Note

      Use a cloth to prevent the shaft snap ring from flying off.

    2. A004KV4

      Remove the washer.

    3. A004KQ1

      Remove the 5th shift head, compression spring and ball.

      Note

      Be careful of the ball and compression spring that fall out when sliding the 5th shift head.

  22. INSPECT COUNTER SHAFT 6TH GEAR THRUST CLEARANCE


    1. A004KICE02

      Using SST and a dial indicator, measure the thrust clearance.

      SST
      09350-20015   ( 09350-06120 )
      Standard clearance
      0.10 to 0.40 mm (0.00394 to 0.0157 in.)
      Maximum clearance
      0.40 mm (0.0157 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the counter shaft 6th gear, No. 4 transmission clutch hub, 6th gear thrust washer, needle roller bearing and counter shaft with a new ones.

  23. INSPECT COUNTER SHAFT 6TH GEAR RADIAL CLEARANCE


    1. A004IVV

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000590 to 0.00268 in.)
      Maximum clearance
      0.068 mm (0.00268 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the counter shaft 6th gear, needle roller bearing and counter shaft with a new ones.

  24. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A004KY5

      Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

      Note

      Use a cloth to prevent the shaft snap ring from flying off.

    2. A004KCZE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST and 3 bolts, remove the No. 4 transmission clutch hub, No.4 transmission hub sleeve, No. 4 gear shift fork and No. 2 gear shift fork shaft all together.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09956-03010 )

  25. REMOVE NO. 4 GEAR SHIFT FORK


    1. for Pin:


      1. A004JBW

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

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

    2. for Bolt:


      1. A004J3Q

        Remove the bolt and No. 4 gear shift fork from the No. 2 gear shift fork shaft.

  26. REMOVE NO. 4 TRANSMISSION HUB SLEEVE


    1. A004JQH

      Using a screwdriver, remove the hole snap ring.

    2. A004KLF

      Remove the No. 4 transmission hub sleeve, and then remove the 3 No. 1 synchromesh shifting keys, 3 No. 1 synchromesh shifting key springs and 3 balls from the No. 4 transmission clutch hub.

      Note


      • Use a cloth to prevent the No. 1 synchromesh shifting keys, No. 1 synchromesh shifting key springs and balls from popping out.

      • Do not deform the No. 1 synchromesh shifting key spring.

      Tech Tips

      During this operation, keep intact the No. 4 transmission clutch hub and No. 1 synchromesh shifting key.

  27. REMOVE NO. 2 SYNCHRONIZER RING


    1. A004KC3

      Remove the No. 2 synchronizer ring.

  28. REMOVE COUNTER SHAFT 6TH GEAR


    1. A004H5F

      Remove the counter shaft 6th gear.

  29. REMOVE NEEDLE ROLLER BEARING


    1. A004HQA

      Remove the needle roller bearing.

  30. REMOVE 6TH GEAR THRUST WASHER


    1. A004KEW

      Remove the 6th gear thrust washer.

    2. A004IXY

      Remove the straight pin.

  31. REMOVE NO. 2 GEAR SHIFT HEAD


    1. A004IZC

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

      Note


      • Use a cloth to prevent the slotted spring pin from flying off.

      • Take care in order that the slotted spring pin does not fall inside through the gear shift fork shaft hole.

    2. Remove the No. 2 gear shift head from the No. 2 gear shift fork shaft.

  32. REMOVE NO. 1 GEAR SHIFT HEAD


    1. A004KW9

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

      Note


      • Use a cloth to prevent the slotted spring pin from flying off.

      • Take care in order that the slotted spring pin does not fall inside through the gear shift fork shaft hole.

    2. Remove the No. 1 gear shift head from the No. 1 gear shift fork shaft.

  33. REMOVE NO. 3 GEAR SHIFT HEAD


    1. A004HKD

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

      Note


      • Use a cloth to prevent the slotted spring pin from flying off.

      • Take care in order that the slotted spring pin does not fall inside through the gear shift fork shaft hole.

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

  34. REMOVE REAR BEARING RETAINER


    1. A004IUY

      Using a T45 "TORX" socket wrench, remove the 4 bolts and rear bearing retainer.

    2. A004J7N

      Remove the shift arm pivot.

  35. REMOVE TRANSMISSION CASE


    1. A004JSY

      Using a snap ring expander, remove the shaft snap ring.

    2. A004H13

      Remove the bolt that retains the reverse idler gear shaft, and the gasket (transmission case side)

    3. A004JN7E01
      Text in Illustration
      *1 Clamp

      Remove the 9 bolts and clamp.

    4. A004HCC

      Using a plastic hammer, remove the transmission case.

      Note

      Do not damage the transmission case.

  36. REMOVE OIL RECEIVER PIPE


    1. A004I89

      Remove the oil receiver pipe.

  37. REMOVE FRONT BEARING RETAINER


    1. A004I52

      Remove 7 bolts and front bearing retainer.

  38. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A004HCOE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the transmission front bearing retainer oil seal.

      Note

      Do not damage the front bearing retainer.

      Tech Tips

      Remove the front bearing retainer while protecting it with a piece of cloth.

  39. REMOVE COUNTER SHAFT


    1. A004JD1

      Using a snap ring expander, remove the 2 shaft snap rings.

      Tech Tips

      Remove the 2 shaft snap rings from the input shaft and counter shaft.

    2. A004IWE

      Remove the bolt and gasket to free the reverse idler gear and reverse idler gear shaft. (Clutch housing side)

    3. A004JZ2

      Using a hammer handle edge, tap to remove the input shaft, output shaft, counter shaft, reverse idler gear, reverse idler gear shaft, No. 1 gear shift fork shaft, No. 2 gear shift fork shaft and No. 3 gear shift fork shaft all together from the clutch housing side.

  40. REMOVE NO. 2 GEAR SHIFT FORK SHAFT


    1. A004HNT

      Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

      Note

      Use a cloth to prevent the shaft snap ring from flying off.

    2. A004KA7

      Remove the bolt and No. 2 gear shift fork shaft.

  41. REMOVE NO. 1 GEAR SHIFT FORK SHAFT


    1. A004KYA

      Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

      Note

      Use a cloth to prevent the shaft snap ring from flying off.

    2. A004IQW

      Remove the No. 1 gear shift fork shaft and No.1 gear shift fork together.

    3. A004JTS

      Using 2 screwdrivers and a plastic hammer, remove the shaft snap ring.

      Note

      Use a cloth to prevent the shaft snap ring from flying off.

    4. A004KST

      Remove the bolt and No. 1 gear shift fork shaft.

  42. REMOVE NO. 3 GEAR SHIFT FORK SHAFT


    1. A004IVS

      Remove the bolt and No. 3 gear shift fork shaft.

  43. REMOVE INPUT SHAFT


    1. A004KPF

      Remove the input shaft from the output shaft.

  44. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A004K7C

      Use a vice to secure the reverse idler gear, and then use a dial indicator to measure the radial clearance.

      Standard clearance
      0.040 to 0.082 mm (0.00157 to 0.00323 in.)
      Maximum clearance
      0.082 mm (0.00323 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the reverse idler gear and reverse idler gear shaft with a new ones.

  45. REMOVE REVERSE IDLER GEAR SHAFT


    1. A004I2V

      Remove the reverse idler gear shaft from the reverse idler gear.