Manual Transaxle Unit Disassembly

Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.

Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.

Remove the release fork support from the manual transaxle case.

Remove the clutch release fork boot from the manual transaxle case.

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

Remove the O-ring.

Remove the 3 bolts and control cable bracket.

Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.

Remove the nut and spring washer.

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

Remove the control shift lever.

Remove the bolt and No. 2 clutch tube bracket.

Place the manual transaxle assembly on wooden blocks.

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

Remove the shift gate pin from the manual transmission case.

Remove the manual transmission breather plug.

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

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

Remove the back-up light switch assembly and gasket from the manual transmission case.

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 10 bolts and manual transmission case cover from the manual transmission case.

Engage the 1st and 2nd gears simultaneously.

Using SST and a hammer, unstake the manual transmission output shaft rear set nut.

SST

09930-00010

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

SST

09229-55010

Disengage the gears.

Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.

HINT:

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

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

Using SST, remove the No. 3 transmission clutch hub 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 5th gear 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 "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.

Remove the output shaft rear bearing shim from the output shaft.

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

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

HINT:

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

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

HINT:

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

Remove the reverse idler gear shaft bolt and gasket.

Remove the 3 bolts from the manual transaxle case.

Remove the 14 bolts from the manual transmission case.

Using a plastic hammer, carefully tap the manual transmission case to remove it.

Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.

Using a pin punch (φ 5 mm) and hammer, remove the slotted pin.

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

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

NOTICE:

Do not damage the pipe.

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

NOTICE:

Do not damage the pipe.

Remove the transmission magnet from the manual transaxle case.

Remove the reverse idler gear sub-assembly from the manual transaxle case.

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

Remove the 2 bolts and reverse shift arm bracket assembly from the manual 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 pulling up the No. 3 gear shift fork shaft.

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

HINT:

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

Using a magnetic pick-up tool, 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 and No. 1 gear shift head from the manual transaxle case.

Remove the No. 1 gear shift fork.

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

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

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

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

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

Lift the differential case assembly while tilting the output shaft assembly.

Remove the output shaft assembly from the manual transaxle case.

Remove the differential case assembly from the manual transaxle case.

Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.

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

SST

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

Using SST, remove the front transaxle case cover oil seal from the manual transaxle case.

SST

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

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

SST

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

Remove the output shaft cover from the manual transaxle case.

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

SST

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

Using SST, remove the transmission case oil seal from the manual transmission case.

SST

09308-00010

Using a screwdriver, remove the transaxle case oil seal.

HINT:

Tape the screwdriver tip before use to avoid damage.

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

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

SST

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

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

SST

09950-60020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00490)

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

Remove the 2 No. 3 synchromesh shifting key springs from the No. 3 transmission 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 from the No. 5 synchronizer ring inner.