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. C194603

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

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

    1. C194604

      Using a 27 mm deep socket wrench, remove the neutral position switch and gasket from the manual transmission case.

  5. REMOVE CONTROL CABLE BRACKET ASSEMBLY

    1. C276945

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

  6. REMOVE WIRE HARNESS CLAMP BRACKET (w/ Stop And Start System)

    1. C194606

      Remove the bolt and wire harness clamp bracket from the manual transmission case.

  7. REMOVE NO. 1 CLUTCH HOUSING COVER

    1. C194612

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

  8. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

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

  9. REMOVE RELEASE CYLINDER BLEEDER PLUG

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

  10. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  11. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  12. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  13. SECURE MANUAL TRANSAXLE ASSEMBLY

    1. C194619C07

      *a

      Wooden Block

      Place the manual transaxle assembly on wooden blocks.

  14. REMOVE TRANSMISSION CASE PLUG

    1. C194614

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

  15. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C386791

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

  16. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C194616

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

  17. REMOVE LOCK BALL PIN

    1. C194617

      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.

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

  19. REMOVE OUTER SHIFT LEVER E-RING

    1. C194622

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

  20. REMOVE MANUAL TRANSMISSION CASE

    1. C327457

      Remove the 16 bolts.

    2. C194621C06

      *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. C194623C01

      *a

      Boss

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

    4. C194624

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

  21. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C194626

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

  22. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. C194627

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

  23. REMOVE REVERSE SHIFT FORK

    1. Secure the No. 4 gear shift fork shaft in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C325135

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

    3. C325136

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

  24. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. C194628

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

  25. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. C194629

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

    2. C194630C01

      *1

      Shift and Select Lever Shaft Assembly

      *2

      Shift Inter Lock Plate

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

    3. Remove the shift inter lock plate from the front transaxle case.

  26. REMOVE OUTER SELECT LEVER

    1. C194631C04

      *a

      Mark

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

  27. REMOVE OUTER SELECT LEVER OIL SEAL

    1. C194642C04

      *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.

  28. REMOVE INPUT SHAFT ASSEMBLY

    1. C194632

      Remove the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly from the front transaxle case.

  29. REMOVE NO. 1 GEAR SHIFT HEAD

    1. Secure the No. 1 gear shift fork assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C325108

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

    3. C325109

      Remove the No. 1 gear shift head from the No. 1 gear shift fork assembly.

  30. REMOVE NO. 2 GEAR SHIFT HEAD

    1. Secure the No. 2 gear shift fork assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C325117

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 2 gear shift head.

    3. C325118

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

  31. REMOVE NO. 2 REVERSE PRE-BALK HEAD

    1. C325119C01

      *1

      Snap Ring

      *a

      Protective Tape

      Using 2 screwdrivers with their tips wrapped with protective tape and a hammer, remove the snap ring from the No. 2 gear shift fork assembly.

      Tip:

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

    2. C325120

      Remove the spacer from the No. 2 gear shift fork assembly.

    3. C325121

      Remove the No. 2 reverse pre-balk head from the No. 2 gear shift fork assembly.

    4. Secure the No. 2 reverse pre-balk head in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    5. C325122

      Using a 3 mm pin punch and a hammer, remove the straight pin from the No. 2 reverse pre-balk head.

    6. C325123C02

      *1

      Bimetal Formed Bushing

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped with protective tape and a hammer, remove the 2 bimetal formed bushings from the No. 2 reverse pre-balk head.

      Note:

      Do not damage the No. 2 reverse pre-balk head.

  32. REMOVE SHIFT LEVER STOPPER

    1. C325125

      Remove the torsion spring from the No. 2 gear shift fork assembly.

    2. C325126

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

    3. C325127

      Remove the shift lever stopper from the No. 2 gear shift fork assembly.

  33. REMOVE NO. 3 GEAR SHIFT HEAD

    1. Secure the No. 3 gear shift fork assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C325111

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

    3. C325112

      Remove the No. 3 gear shift head from the No. 3 gear shift fork assembly.

  34. REMOVE NO. 3 REVERSE PRE-BALK HEAD

    1. C325114

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 reverse pre-balk head.

    2. C325115

      Remove the No. 3 reverse pre-balk head from the No. 3 gear shift fork assembly.

  35. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C194633

      Remove the differential case assembly from the front transaxle case.

  36. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. C194639N03

      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. C193754C04

      *a

      Hold

      *b

      Turn

      Using SST, remove the front differential case front tapered roller bearing (inner race) 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

  37. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. C194651N03

      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. C193753C04

      *a

      Hold

      *b

      Turn

      Using SST, remove the front differential case rear tapered roller bearing (inner race) 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

  38. REMOVE TRANSMISSION MAGNET

    1. C194634

      Remove the transmission magnet from the front transaxle case.

  39. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194635

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

  40. REMOVE BREATHER PLUG

    1. C194636

      Remove the breather plug from the front transaxle case.

  41. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)

    1. C194637N03

      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.

  42. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. C194641N03

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

      09950-60010

      09951-00360

      09950-70010

      09951-07150

  43. REMOVE REVERSE RESTRICT PIN ASSEMBLY

    1. C195992

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

  44. REMOVE STRAIGHT PIN

    1. C202594

      Remove the 5 straight pins from the front transaxle case.

  45. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. C194644

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

  46. REMOVE INPUT SHAFT COVER

    1. A295612

      Remove the input shaft cover from the manual transmission case.

  47. REMOVE NO. 1 OIL RECEIVER PIPE

    1. C194646

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

  48. REMOVE TRANSMISSION OIL SEPARATOR

    1. C194647

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

  49. 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.

  50. REMOVE OUTER NO. 1 SHIFT LEVER

    1. C197467

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

      Tip:

      When removing the inner shift lever slotted spring pin, align the inner shift lever slotted spring 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.

  51. REMOVE OUTER SHIFT LEVER OIL SEAL

    1. C194653C04

      *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.

  52. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)

    1. C194650N06

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

      09308-00010

  53. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

    1. C194652N03

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

      09950-60010

      09951-00620

      09950-70010

      09951-07150

  54. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

    1. C201402N03

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

      09950-60010

      09951-00530

      09950-70010

      09951-07150