MANUAL TRANSAXLE UNIT > DISASSEMBLY

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1. REMOVE MANUAL TRANSMISSION FILLER PLUG


    C195440

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



2. REMOVE MANUAL TRANSMISSION DRAIN PLUG


    C195441

  1. Using a socket hexagon 10 mm, remove the manual transmission drain plug and gasket from the front transaxle case.



3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


    C198727

  1. Separate the 3 clamps and back up light switch wire harness.



    C195443E01

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

    SST
    09817-16011  



4. REMOVE WIRE HARNESS CLAMP BRACKET


    C195442

  1. Remove the wire harness clamp bracket as shown in the illustration.



    C195444

  1. Remove the wire harness clamp bracket for back-up light switch as shown in the illustration.



5. REMOVE NO. 1 CLUTCH HOUSING COVER


C198729

  1. Remove the No. 1 clutch housing cover from the transaxle.



6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


C195353

  1. Using a union nut wrench 10 mm, separate the clutch release bleeder from the bleeder clutch release tube.

  1. Remove the 2 bolts and clutch release bleeder.



7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

  1. Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.



8. REMOVE CLUTCH TUBE BOOT

  1. Remove the clutch tube boot from the transaxle.



9. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


C198620

  1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.



10. REMOVE BLEEDER CLUTCH RELEASE TUBE


C195450

  1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.



11. SECURE MANUAL TRANSAXLE ASSEMBLY


    C198621E01

  1. Place the manual transaxle assembly on wooden blocks.
    Text in Illustration 
    *1
    		Wooden blocks



12. REMOVE NO. 1 TRANSMISSION CASE PLUG


    C198622

  1. Using a 30 mm socket wrench, remove the No. 1 transmission case plug and gasket.



13. REMOVE TRANSMISSION CASE PLUG


  1. for manual transmission case upper side



      C198623

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



  1. for manual transmission case rear side



      C198624

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



14. REMOVE NO. 1 LOCK BALL ASSEMBLY


    C198625

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



15. REMOVE REVERSE IDLER GEAR SHAFT BOLT


    C198626

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



16. REMOVE LOCK BALL PIN


    C198629

  1. Using a socket hexagon 10 mm, remove the plug from the manual transmission case.

  1. Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.



17. REMOVE SHIFT DETENT BALL


    C198631

  1. Using a socket hexagon 6 mm, remove the shift detent ball plug from the manual transmission case.

  1. Using a magnet hand, remove the shift detent ball compression spring and shift detent ball from the manual transmission case.



    C198633

  1. Using a socket hexagon 6 mm, remove the 2 shift detent ball plugs from the manual transmission case.

  1. Using a magnet hand, remove the 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.



18. REMOVE OUTER SHIFT LEVER E RING


    C198634

  1. Remove the outer shift lever E ring from the outer No. 1 shift lever.



19. REMOVE MANUAL TRANSMISSION CASE


    C198635

  1. Remove the 16 bolts.



    C198636E01

  1. Using a screwdriver with its tip wrapped with protective tape, separate the manual transmission case from the front transaxle case.
    Text in Illustration 
    *1
    		Protective tape

    NOTICE:
    Do not damage the manual transmission case.



    C198637E03

  1. Push the outer No. 1 shift lever.
    Text in Illustration 
    *1
    		Outer No. 1 shift lever
    *2
    		Push
    *3
    		Turn

  1. Turn the outer No. 1 shift lever counterclockwise and remove the manual transmission case.



20. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY


    C198640E02

  1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the front transaxle case.
    Text in Illustration 
    *1
    		Reverse idler gear shaft
    *2
    		Thrust washer
    *3
    		Reverse idler gear sub-assembly



21. REMOVE REVERSE SHIFT FORK SHAFT ASSEMBLY


    C198641

  1. Turn the reverse shift fork shaft assembly counterclockwise and remove it from the front transaxle case.



22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY


    C198643

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



23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    C198645

  1. Turn the shift and select lever shaft assembly clockwise and remove the shift and select lever shaft from the front transaxle case.



24. REMOVE SHIFT INTER LOCK PLATE


    C198647

  1. Remove the shift inter lock plate.



25. REMOVE OUTER SELECT LEVER


    C198648

  1. Using a socket hexagon 6 mm, remove the inner select lever set bolt.



    C198649E01

  1. Remove the outer select lever and inner select lever from the front transaxle case.
    Text in Illustration 
    *1
    		Inner select lever
    *2
    		Outer select lever



26. REMOVE OUTER SELECT LEVER OIL SEAL


    C198650E01

  1. Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the front transaxle case.
    Text in Illustration 
    *1
    		Protective tape

    NOTICE:
    Do not damage the installation surfaces.



27. REMOVE INPUT SHAFT ASSEMBLY


    C198652

  1. Remove the input shaft assembly, output shaft assembly and 3 gear shift fork shaft assemblies from the front transaxle case.



28. REMOVE DIFFERENTIAL CASE ASSEMBLY


    C198656

  1. Remove the differential case assembly from the front transaxle case.



29. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    C198658E01

  1. Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case front plate washer from the front transaxle case.
    Text in Illustration 
    *1
    		Front differential case front tapered roller bearing (outer race)
    *2
    		Front differential case front plate washer

    SST
    09308-00010  



    C193754E05

  1. Using SST, remove the front differential case front tapered roller bearing from the differential case assembly.
    Text in Illustration 
    *1
    		Hold
    *2
    		Turn

    SST
    09950-40011   (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
    09950-60010   (09951-00390)



30. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    C198669E01

  1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear plate washer from the manual transmission case.
    Text in Illustration 
    *1
    		Front differential case rear tapered roller bearing (outer race)
    *2
    		Front differential case rear plate washer

    SST
    09308-00010  



    C193753E03

  1. Using SST, remove the front differential case rear tapered roller bearing from the front differential case.
    Text in Illustration 
    *1
    		Hold
    *2
    		Turn

    SST
    09950-40011   (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
    09950-60010   (09951-00390)



31. REMOVE TRANSMISSION MAGNET


    C198655

  1. Remove the transmission magnet from the front transaxle case.



32. REMOVE TRANSMISSION OIL SEPARATOR


    C198657

  1. Remove the 3 bolts and transmission oil separator from the front transaxle case.



33. REMOVE FRONT OUTPUT SHAFT BEARING


C198660E01
Text in Illustration 
*1
Front output shaft bearing (outer race)
*2
Output shaft cover

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

    SST
    09308-00010  



34. REMOVE FRONT TRANSAXLE CASE OIL SEAL


    C198664E01

  1. Remove the front transaxle case oil seal from the front transaxle case.

    SST
    09950-60010   (09951-00360)
    09950-70010   (09951-07150)



35. REMOVE REVERSE RESTRICT PIN ASSEMBLY


    C198666

  1. Remove the reverse restrict pin assembly from the front transaxle case.



36. REMOVE STRAIGHT PIN


    C198667

  1. Remove the 4 straight pins from the front transaxle case.



37. REMOVE REAR INPUT SHAFT BEARING SHIM


    C198671

  1. Remove the rear input shaft bearing shim from the manual transmission case.



38. REMOVE INPUT SHAFT COVER


    C198672

  1. Remove the input shaft cover from the manual transmission case.



39. REMOVE NO. 1 OIL RECEIVER PIPE


    C198673

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



40. REMOVE NO. 1 TRANSMISSION OIL SEPARATOR


    C198674

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



41. REMOVE MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    C198676

  1. Remove the bolt and manual transmission oil separator sub-assembly from the manual transmission case.



42. REMOVE NO. 2 TRANSMISSION OIL SEPARATOR


    C198677

  1. Remove the 2 bolts and No. 2 transmission oil separator.



43. REMOVE OUTER NO. 1 SHIFT LEVER


    C198681

  1. Using a pin punch 5 mm and a hammer, remove the inner shift lever slotted spring pin.

    HINT:
    When removing the slotted spring pin, align the pin with the hole in the No. 1 lock ball assembly.

  1. Remove the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever from the manual transmission case.



44. REMOVE OUTER SHIFT LEVER OIL SEAL


    C198682E01

  1. Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the manual transmission case.
    Text in Illustration 
    *1
    		Protective tape

    NOTICE:
    Do not damage the installation surfaces.



45. REMOVE REAR OUTPUT SHAFT BEARING


    C198678E01

  1. Using SST, remove the rear output shaft bearing (outer race) and rear output shaft bearing shim from the manual transmission case.
    Text in Illustration 
    *1
    		Rear output shaft bearing (outer race)
    *2
    		Rear output shaft bearing shim

    SST
    09308-00010  



46. REMOVE TRANSMISSION CASE OIL SEAL


    C198686E01

  1. Remove the transmission case oil seal from the manual transmission case.

    SST
    09950-60010   (09951-00620)
    09950-70010   (09951-07150)



47. REMOVE TRANSAXLE CASE OIL SEAL


    C198665E01

  1. 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)



48. REMOVE BREATHER PLUG


    C198684

  1. Remove the breather plug from the front transaxle case.