MANUAL TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE MANUAL TRANSMISSION FILLER PLUG

    1. C194601

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

  2. REMOVE MANUAL TRANSMISSION DRAIN PLUG

    1. C194602

      Using a 10 mm hexagon socket wrench, remove the manual transmission drain plug and gasket from the front transaxle case.

  3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C197871

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

  4. REMOVE MANUAL TRANSMISSION CASE PLUG

    1. C206934

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

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY

    1. C197872

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

  6. REMOVE NO. 1 CLUTCH HOUSING COVER

    1. C197873

      Remove the No. 1 clutch housing cover from the front transaxle 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

    Click here

  10. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  11. SECURE MANUAL TRANSAXLE ASSEMBLY

    1. C197874

      Place the manual transaxle assembly on wooden blocks.

  12. REMOVE TRANSMISSION CASE PLUG

    1. C194614

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

  13. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C194615

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

  14. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C194616

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

  15. REMOVE LOCK BALL PIN

    1. C194617

      Using a 10 mm hexagon socket wrench, remove the plug from the manual transmission case.

    2. Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.

  16. REMOVE SHIFT DETENT BALL

    1. C194618

      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 compression spring and shift detent ball from the manual transmission case.

    3. C194778

      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 compression springs and 2 shift detent balls from the manual transmission case.

  17. REMOVE OUTER SHIFT LEVER E RING

    1. C197875

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

  18. REMOVE MANUAL TRANSMISSION CASE

    1. C197876

      Remove the 16 bolts.

    2. C197877E01

      Using a screwdriver with its tip wrapped with protective tape, separate the manual transmission case from the front transaxle case.

      Table 1. Text in Illustration

      *1

      Protective Tape
      Note:

      Do not damage the manual transmission case.

    3. C197878E01

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

      Table 2. Text in Illustration

      *1

      Boss
    4. C197879

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

  19. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C197880

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

  20. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. C197881

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

  21. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. C197882

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

  22. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. C194629

      Using a 6 mm hexagon socket wrench, remove the inner select lever set bolt.

    2. C197883

      Turn the shift and select lever shaft assembly and shift interlock plate clockwise and remove them from the front transaxle case.

  23. REMOVE OUTER SELECT LEVER

    1. C197884E01

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

      Table 3. Text in Illustration

      *1

      Mark

  24. REMOVE OUTER SELECT LEVER OIL SEAL

    1. C197885E02

      Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the front transaxle case.

      Table 4. Text in Illustration

      *1

      Protective Tape
      Note:

      Do not damage the installation surfaces.

  25. REMOVE INPUT SHAFT ASSEMBLY

    1. C197886

      Remove the input shaft assembly, output shaft assembly and 3 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 and No. 3 gear shift fork shaft assemblies from the input shaft assembly.

  26. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C197887

      Remove the differential case assembly from the front transaxle case.

  27. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C197888E01

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

      09308-00010

    2. C193754E14

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00390

      Table 5. Text in Illustration

      *1

      Turn

      *2

      Hold

  28. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. C194651E04

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

      09308-00010

    2. C193753E02

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00390

      Table 6. Text in Illustration

      *1

      Turn

      *2

      Hold

  29. REMOVE TRANSMISSION MAGNET

    1. C194634

      Remove the transmission magnet from the front transaxle case.

  30. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194635

      for Front Transaxle Case Side:

      Remove the 4 bolts and transmission oil separator from the front transaxle case.

  31. REMOVE BREATHER PLUG

    1. C197889

      Remove the breather plug from the front transaxle case.

  32. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C197890E02

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

      09308-00010

    2. C194638

      Remove the output shaft cover from the front transaxle case.

  33. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C197891E02

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

      09950-60010

      09951-00360

      09950-70010

      09951-07150

  34. REMOVE REVERSE RESTRICT PIN ASSEMBLY

    1. C195992

      Remove the reverse restrict pin assembly from the front transaxle case.

  35. REMOVE STRAIGHT PIN

    1. C205127

      Remove the 5 straight pins from the front transaxle case.

  36. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. C194644

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

  37. REMOVE INPUT SHAFT COVER

    1. C363626

      Remove the input shaft cover from the manual transmission case.

  38. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C194646

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

  39. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194647

      For manual transmission case side:

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

  40. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY

    1. C194648

      Remove the 4 bolts and manual transmission oil separator sub-assembly from the manual transmission case.

  41. REMOVE OUTER NO. 1 SHIFT LEVER

    1. C197467

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

      Tip:

      When removing the slotted spring pin, align the pin with the hole in the No. 1 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.

  42. REMOVE OUTER SHIFT LEVER OIL SEAL

    1. C194653E02

      Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the front transaxle case.

      Table 7. Text in Illustration

      *1

      Protective Tape
      Note:

      Do not damage the installation surfaces.

  43. REMOVE REAR OUTPUT SHAFT BEARING

    1. C194650E06

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

      09308-00010

  44. REMOVE TRANSMISSION CASE OIL SEAL

    1. C194652E01

      Using SST, remove the transmission case oil seal from the manual transmission case.

      09950-60010

      09951-00620

      09950-70010

      09951-07150

  45. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C194640E01

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

      09950-60010

      09951-00530

      09950-70010

      09951-07150