Manual Transaxle Unit 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.

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, nut and selecting bellcrank assembly from the manual transmission case.

Remove the control bellcrank dust cover.

Remove the nut and washer.

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

Remove the floor shift control shift lever and dust boot.

Remove the nut and washer.

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

Remove the shift lever damper and dust boot.

Place the manual transaxle assembly on wooden blocks.

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

Remove the shift guide pin and washer from the manual 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 manual transmission case.

Remove the 9 bolts.

Using a plastic hammer, carefully tap the projections 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 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 the No. 3 gear shift fork.

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

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

Standard clearance:

0.10 to 0.55 mm (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

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

Standard clearance:

NSK made bearing:

0.015 to 0.056 mm (0.000591 to 0.00220 in.)

JTEKT made bearing:

0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing:

0.056 mm (0.00220 in.)

JTEKT made bearing:

0.058 mm (0.00228 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 No. 3 transmission clutch hub.

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

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(09951-00180,09952-06010)

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

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

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 pick-up tool, remove the 2 shift spring seats, 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 transaxle case.

Using a magnetic pick-up tool, remove the seat, spring and ball from the transaxle case.

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

Remove the 3 bolts from the 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 or transaxle case.

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

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

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

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

Remove the No. 1 gear shift fork.

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

HINT:

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

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

Using a magnetic pick-up tool, remove the 2 reverse shift fork balls from the reverse shift fork.

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

HINT:

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

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

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

Remove the differential case assembly from the transaxle case.

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

Using a hexagon wrench, remove the reverse restrict pin assembly 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 No. 1 oil receiver pipe from the manual transmission case.

NOTICE:

Do not damage the No. 1 oil receiver pipe.

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

NOTICE:

Do not damage the No. 2 oil receiver pipe.

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

Remove the transmission magnet from the transaxle case.

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

SST

09308-00010

NOTICE:

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

Remove the output shaft cover from the transaxle case.

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

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

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

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

SST

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