Manual Transaxle Unit Disassembly

Remove the clutch release fork with the clutch release bearing from the transaxle case.

Remove the release bearing and clutch release bearing hub clip from the clutch release fork.

Remove the clutch release fork support from the transaxle case.

Remove the clutch release fork boot from the transaxle case.

Remove the bolt and hole cover.

Remove the O-ring from the hole cover.

Remove the 2 bolts and selecting bellcrank from the transaxle case.

Remove the shift and select lever bush from the selecting bellcrank.

Remove the nut and spring washer.

Using a brass bar and hammer, tap out the shift outer lever lever lock pin.

Remove the control shift lever.

Remove the 4 bolts, control shift cover and gasket from the transaxle case.

Place the transaxle on wooden blocks.

Remove the lock ball from the transaxle case.

Remove the breather plug and gasket.

Remove the shift and select lever shaft from the transaxle case.

Remove the back-up light switch and gasket from the transaxle case.

Remove the filler plug and gasket from the transaxle case.

Remove the drain plug and gasket from the transaxle case.

Remove the 10 bolts and transaxle case cover from the transaxle case.

Engage the 2 gears simultaneously to lock the transaxle.

Using SST and a hammer, unstake the rear set nut.

SST

09930-00010

Using SST, remove the shaft rear set nut from the output shaft.

SST

09229-55010

Disengage the 2 gears.

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.65 mm (0.0039 to 0.0256 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

Using 2 screwdrivers and a hammer, tap out the No. 3 transaxle clutch hub shaft snap ring from the input shaft.

HINT:

Cover with a shop rag to keep the snap ring from flying off.

Remove the shift fork set bolt from the No. 3 gear shift fork.

Using SST, remove the No. 3 transaxle clutch hub, No. 3 transaxle hub sleeve and No. 3 gear shift fork from the input shaft.

SST

09950-30012(09951-03010,09953-03010,09954-03010)
09950-50013(09957-04010)
09950-60010(09951-00280)

Remove the 5th gear from the input shaft.

Remove the needle roller bearing from the input shaft.

Using SST, remove the 5th driven gear from the output shaft.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09957-04010)
09950-60010(09951-00180,09955-03011)
09950-50013

Using a T45 "torx" socket, remove the 7 "torx" screws and bearing retainer from the transaxle case.

Remove the rear bearing shim from the output shaft.

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

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

HINT:

Cover with a shop rag to keep the snap ring from flying off.

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

HINT:

Cover with a shop rag to keep the snap ring from flying off.

Remove the reverse idler gear shaft bolt and gasket.

Remove the bolt and clutch tube bracket.

Remove the 3 bolts from the transaxle case side.

Remove the 14 bolts from the transaxle case side.

Remove the transaxle case by tapping it using a plastic-faced hammer.

Remove the bolt and oil receiver pipe from the transaxle case.

NOTICE:

Do not damage the pipe.

Remove the bolt and oil receiver pipe from the transaxle case.

NOTICE:

Do not damage the pipe.

Using a 6 mm hexagon wrench, remove the restrict pin plug from the transaxle case.

Using a 5 mm pin punch and hammer, tap out the slotted pin.

Remove the reverse restrict pin.

Remove the bolt, transmission oil baffle and reverse restrict pin.

Remove the magnet from the transaxle case.

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

Remove the reverse idler gear and reverse idler thrust washer from the gear shaft.

Remove the 2 bolts and arm bracket from the transaxle case.

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

Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shift is pulled up.

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

HINT:

Cover with a shop rag to keep the snap ring from flying off.

Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.

Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.

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

Remove the No. 3 gear shift fork shaft from the transaxle case.

Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.

HINT:

Cover with a shop rag to keep the snap ring from flying off.

Remove the reverse shift fork from the No. 3 gear shift fork shaft.

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

Tilt the output shaft, then remove the input shaft from the transaxle case.

Slightly lift up on the differential case with the output shaft at an angle.

Remove the output shaft from the transaxle case.

Remove the differential case from the transaxle case.

Remove the 3 bolts and receiver from the transaxle case.

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

SST

09612-65014(09612-01040,09612-01050)

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

SST

09612-65014(09612-01040,09612-01050)

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

SST

09387-00041(09387-02020,09387-02010)

Remove the output shaft cover from the transaxle case.

Using SST, tap out the rear bearing from the transaxle case (outer race).

SST

09950-60010(09951-00680)
09950-70010(09951-07100)

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

SST

09308-00010

Using a screwdriver, pry out the cover oil seal.

HINT:

Tape the screwdriver tip before use to avoid damage.

Using a brass bar and hammer, tap out the front tapered roller bearing (outer race) from the transaxle case.

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

SST

09950-00020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00560)

Using SST and a hammer, tap out the rear tapered roller bearing (outer race) and rear shim from the transaxle case.

SST

09950-60020(09951-00790)
09950-70010(09951-07100)

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

SST

09950-00020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00490)

Remove the No. 3 transaxle hub sleeve from the No. 3 transaxle clutch hub.

Remove the 2 No. 3 synchromesh shifting key springs and synchronizer ring set from the No. 3 transaxle clutch hub while pushing on the No. 3 synchromesh shifting key spring.

Using a screwdriver, remove the synchronizer pull ring snap ring.

Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner and No. 5 synchronizer ring middle.