Manual Transaxle Unit Disassembly

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

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

Remove the release fork support from the transaxle case.

Remove the clutch release fork boot from the transaxle case.

Remove the 3 bolts and floor shift control lever housing support bracket from the manual transaxle.

Remove the 2 bolts and selecting bell crank from the transmission case.

Using SST, remove the back-up light switch and gasket.

Специальный инструмент (SST):

09816-30010

Remove the lock ball from the transmission case.

Remove the lock ball from the transmission case.

Remove the shift gate pin from the transmission case.

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

While pressing the shift and select pin (*1) in as much as possible, pull the shift and select pin (*2).

Remove the spring.

Remove the O-ring from the shift and select pin.

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

Remove the drain plug and gasket from the front transaxle case.

Using a hexagon wrench, remove the 4 shift detent ball plugs from the front transaxle case.

Using a magnetic finger, remove the 4 spring seats and balls.

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

Remove the transmission case plugs from the transmission case.

Remove the 6 bolts from the front transaxle case side.

Remove the 12 bolts from the transmission case side.

Use 2 snap ring pliers to keep the snap ring stretched and remove the transmission case.

Remove the receiver pipe from the transmission case.

ПРИМЕЧАНИЕ:

Do not damage the No. 1 oil receiver pipe.

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

Remove the bolt of the 1st and 2nd shift fork shaft.

Remove the 1st and 2nd shift fork shaft.

Using a pin punch and hammer, tap out the slotted spring pin from the No. 2 gear shift head.

Using a pin punch and hammer, tap out the slotted spring pin from the No. 2 gear shaft fork.

Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head.

Remove the No. 2 gear shift fork from the No. 1 output shaft.

Using a screwdriver, pry out the E-ring from the front transaxle case.

Remove the pin from the front transaxle case.

Remove the No. 5 shift fork shaft from the front transaxle case.

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

Remove the No. 3 gear shift head.

Remove the No. 1 gear shift fork from the No. 1 output shaft.

Remove the shift arm from the front transaxle case.

Remove the bolt of the reverse shift fork shaft.

Remove the reverse shift fork shaft.

Remove the bolt of the No. 3 gear shift fork.

Remove the 5th and 6th shift fork shaft.

Remove the No. 3 gear shift fork from the No. 2 output shaft.

Remove the reverse shift fork from the No. 2 output shaft.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.40 to 1.05 mm (0.0016 to 0.0413 in.)

Maximum clearance:

1.05 mm (0.0413 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.048 mm (0.0006 to 0.0019 in.)

Maximum clearance:

0.048 mm (0.0019 in.)

Remove the reverse idler gear shaft by sliding and lifting it.

Remove the reverse idler gear, needle roller bearing and reverse idler thrust washer from the reverse idler gear shaft.

Remove the 3 shafts at the same time.

Remove the 2 bolts and oil separator from the front transaxle case.

Remove the differential case from the front transaxle case.

Remove the transmission magnet from the front transaxle case.

Using SST, remove the outer race the transmission case.

Специальный инструмент (SST):

09387-00041(09387-02020)

Remove the rear bearing shim from the transmission case.

Using SST, remove the 4 shift fork shaft bearings from the transmission case.

Специальный инструмент (SST):

09612-65014
09387-00041(09387-01021)
09527-20011

Using SST, remove the shift and select lever shaft needle roller bearing from the transmission case.

Специальный инструмент (SST):

09612-65014
09387-00041(09387-01021)

Using snap ring pliers, remove the 2 snap rings.

Remove the bolt from the front transaxle case.

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

Специальный инструмент (SST):

09612-30012

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

Remove the bolt from the front transaxle case.

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

Специальный инструмент (SST):

09612-65014(09612-01020)

Remove the output shaft cover from the front transaxle case.

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

Специальный инструмент (SST):

09387-00041(09387-02020)

Remove the output shaft cover from the front transaxle case.

Using SST, remove the 4 bearings from the front transaxle case.

Специальный инструмент (SST):

09612-65014
09387-00041(09387-01021)

Using a screwdriver, pry out the oil seal from the transmission case.

Using a brass bar and hammer, tap out the front differential case rear outer race bearing and front differential case rear shim from the transmission case.

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

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

Специальный инструмент (SST):

09387-00041(09387-02020)