Manual Transaxle Unit: Disassembly
- REMOVE MANUAL TRANSMISSION FILLER PLUG
- Remove the manual transmission filler plug and gasket from the manual transmission case.
- REMOVE DRAIN PLUG SUB-ASSEMBLY
- Remove the drain plug sub-assembly and gasket from the manual transmission case.
- REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
- 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 BACK-UP LIGHT SWITCH 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 SELECTING BELLCRANK ASSEMBLY
- Remove the 2 bolts, nut and selecting bellcrank assembly from the manual transmission case.
- Remove the control bellcrank dust cover.
- REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
- 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 SHIFT LEVER DAMPER
- Remove the nut and washer.
- Using a brass bar and a hammer, remove the lock pin.
- Remove the shift lever damper and dust boot.
- PREPARE MANUAL TRANSAXLE ASSEMBLY
- Place the manual transaxle assembly on wooden blocks.
- REMOVE NO. 1 LOCK BALL ASSEMBLY
- Remove the No. 1 lock ball assembly from the manual transmission case.
- REMOVE SHIFT GUIDE PIN
- Remove the shift guide pin and washer from the manual transmission case.
- REMOVE CONTROL SHAFT COVER
- Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.
- REMOVE CONTROL SHAFT COVER OIL SEAL
- Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
- REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
- Remove the shift and select lever shaft assembly from the manual transmission case.
- REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
- 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.NOTE: Do not damage the manual transmission case.
- REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
- 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 NO. 3 GEAR SHIFT FORK
- 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.
- INSPECT 5TH GEAR THRUST CLEARANCE
- 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.)
If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.
- Using a dial indicator, measure the 5th gear thrust clearance.
- INSPECT 5TH GEAR RADIAL CLEARANCE
- 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.)
KOYO 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.)
KOYO made bearing:
0.058 mm (0.00228 in.)
If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.
- Using a dial indicator, measure the 5th gear radial clearance.
- REMOVE NO. 3 TRANSMISSION CLUTCH HUB
- 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.
- Using 2 screwdrivers and a hammer, tap out the snap ring.
- REMOVE 5TH GEAR NEEDLE ROLLER BEARING
- Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
- REMOVE 5TH DRIVEN GEAR
- 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)
- Using SST, remove the 5th driven gear from the output shaft.
- REMOVE REAR BEARING RETAINER
- Remove the 5 bolts and rear bearing retainer from the manual transmission case.
- REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
- Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
- REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
- Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
- REMOVE REVERSE IDLER GEAR SHAFT BOLT
- Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
- REMOVE SHIFT FORK SHAFT SNAP RING
- 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 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.
- REMOVE SHIFT DETENT BALL
- 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.
- REMOVE NO. 2 LOCK BALL ASSEMBLY
- Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.
- REMOVE 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.NOTE: Do not damage the manual transmission case or transaxle case.
- REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
- Remove the reverse idler gear sub-assembly, thrust washer, and reverse idler gear shaft from the transaxle case.
- REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
- Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.
- REMOVE NO. 2 GEAR SHIFT FORK SHAFT
- 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.
- REMOVE NO. 1 GEAR SHIFT FORK SHAFT
- 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.
- REMOVE NO. 3 GEAR SHIFT FORK SHAFT
- 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.
- Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
- REMOVE INPUT SHAFT ASSEMBLY
- Remove the input shaft assembly and output shaft assembly from the transaxle case.
- REMOVE DIFFERENTIAL CASE ASSEMBLY
- Remove the differential case assembly from the transaxle case.
- REMOVE MANUAL TRANSAXLE CASE RECEIVER
- Remove the bolt and manual transaxle case receiver from the transaxle case.
- REMOVE REVERSE RESTRICT PIN ASSEMBLY
- Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
- Using a pin punch ( ø5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.
- REMOVE NO. 1 OIL RECEIVER PIPE
- Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.NOTE: Do not damage the No. 1 oil receiver pipe.
- Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.
- REMOVE NO. 2 OIL RECEIVER PIPE
- Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.NOTE: Do not damage the No. 2 oil receiver pipe.
- Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.
- REMOVE BEARING LOCK PLATE
- Remove the bolt and bearing lock plate from the transaxle case.
- REMOVE TRANSMISSION MAGNET
- Remove the transmission magnet from the transaxle case.
- REMOVE INPUT SHAFT FRONT BEARING
- Using SST, remove the input shaft front bearing from the transaxle case.
SST 09612-65014 (09612-01050, 09612-01060)
- Using SST, remove the input shaft front bearing from the transaxle case.
- REMOVE FRONT TRANSAXLE CASE OIL SEAL
- Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
- REMOVE OUTPUT SHAFT FRONT BEARING
- Using SST, remove the output shaft front bearing from the transaxle case.
SST 09308-00010
NOTE: Do not apply excessive force to the front transaxle case when installing SST.
- Using SST, remove the output shaft front bearing from the transaxle case.
- REMOVE OUTPUT SHAFT COVER
- Remove the output shaft cover from the transaxle case.
- REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
- 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, remove the front differential case front tapered roller bearing (outer race) and plate washer from the transaxle case.
- REMOVE TRANSAXLE CASE OIL SEAL
- 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 and a hammer, remove the transaxle case oil seal from the transaxle case.
- REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
- 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, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
- REMOVE TRANSMISSION CASE OIL SEAL
- 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 SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
- REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL
- Using a screwdriver and a hammer, remove the shift and select lever shaft oil seal.
- REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
- 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)
- Using SST and a plastic hammer, remove the shift and select lever shaft slide ball bearing.