Manual Transaxle Unit (For Sedan) Disassembly

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

Remove the drain plug sub-assembly and gasket from the manual transmission case.

Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.

Remove the O-ring from the speedometer driven hole cover sub-assembly.

Remove the bolt and speedometer sensor from the transaxle case.

Separate the back-up light switch wire harness from the 2 clamps.

Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

SST

09817-16011

Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.

Remove the control shift lever bush.

Remove the nut and spring washer.

Using a brass bar and a hammer, remove the lock pin.

Remove the floor shift control shift lever.

Remove the nut and spring washer.

Using a brass bar and a hammer, remove the lock pin.

Remove the shift lever damper.

Place the manual transaxle assembly on wooden blocks.

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

Remove the shift gate pin and washer from the transmission case.

Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.

Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.

Remove the shift and select lever shaft assembly from the transmission case.

Remove the 9 bolts.

Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.

NOTICE:

Do not damage the manual transmission case.

Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.

Engage the 2 gears simultaneously to lock the transmission.

Remove the manual transmission output shaft rear set nut.

Disengage the 2 gears.

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

Remove transmission hub sleeve No. 3 with gear shift fork No. 3 from transmission clutch hub No. 3.

Using a dial indicator, measure the 5th gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT:

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

Using a screwdriver, remove the synchromesh shifting key spring from the transmission clutch hub No. 3.

Using SST, remove the transmission clutch hub No. 3, 5th gear, and synchronizer ring No. 3 from the input shaft.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05031,09957-04010)
09950-60010(09951-00200)

Remove the 3 synchromesh shifting keys and synchromesh shifting key spring from the transmission clutch hub No. 3.

Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.

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

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03021)
09950-60010(09951-00180)

Remove the 5 bolts and bearing retainer rear from the manual transmission case.

Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.

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

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

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

HINT:

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

Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.

Using a magnetic finger, remove the 2 shift detent ball spring seats No. 1, 2 shift detent ball springs and 2 shift detent balls from the manual transmission case.

Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.

Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.

Using a hexagon wrench, remove lock ball assembly No. 2 from the manual transmission case.

Remove the 3 bolts from the front transaxle case.

Remove the 13 bolts from the manual transmission case.

Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.

NOTICE:

Do not damage the manual transmission case and transaxle case.

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

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

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

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

Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT:

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

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

Remove gear shift fork No. 1.

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

HINT:

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

Remove shift fork shaft No. 3 together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.

Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.

Using 2 screwdrivers and a hammer, tap the snap ring out of shift fork shaft No. 3.

HINT:

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

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

Remove the input shaft assembly and output shaft assembly from the front transaxle case.

Remove the differential case assembly from the front transaxle case.

Remove the bolt and manual transaxle case receiver from the front transaxle case.

Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.

Using a pin punch (φ5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.

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

NOTICE:

Do not damage oil receiver pipe No. 1.

Remove the bolt and oil receiver pipe No. 2 from the manual transmission case.

NOTICE:

Do not damage oil receiver pipe No. 2.

Remove the bolt and bearing lock plate from the front transaxle case.

Remove the transmission magnet from the front transaxle case.

Using SST, remove the input shaft front bearing from the front transaxle case.

SST

09612-65014(09612-01050,09612-01060)

Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.

Using SST, remove the output shaft front bearing from the front transaxle case.

SST

09308-00010

NOTICE:

Do not apply excessive force to the front transaxle case when installing it.

Remove the output shaft cover from the front transaxle case.

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

SST

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

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

SST

09950-00020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00360)

NOTICE:

Do not damage the bearing.

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

SST

09950-60010(09951-00530)
09950-70010(09951-07150)

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

SST

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

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

SST

09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00360)

NOTICE:

Do not damage the bearing.

Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.

SST

09950-60010(09951-00530)
09950-70010(09951-07150)

Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.

Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.

SST

09950-60010(09951-00220)
09950-70010(09951-07200)