Transmission Disassembly

DISASSEMBLY





1. REMOVE CLUTCH RELEASE FORK SUBASSEMBLY
(a) Remove the clutch release fork subassembly together with the clutch release bearing assembly from the manual transaxle case.
2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork subassembly.





3. REMOVE RELEASE FORK SUPPORT
(a) Remove the release fork support from the manual transaxle case.
4. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the manual transaxle case.
5. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUBASSEMBLY
(a) Remove the bolt and speedometer driven (MTM) gear subassembly.
(b) Remove the MTM speedometer shaft sleeve clip, and remove the speedometer driven gear from the speedometer sensor.





6. REMOVE SELECTING BELL CRANK ASSEMBLY
(a) Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.





7. REMOVE CONTROL SHIFT LEVER
(a) Remove the nut and spring washer.





(b) Using a brass bar and hammer, remove the shift outer lever lever lock pin.
(c) Remove the control shift lever.





8. REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts and control shaft cover from the manual transmission case.





9. FIX MANUAL TRANSAXLE ASSEMBLY
(a) Place the manual transaxle assembly on wooden blocks.





10. REMOVE LOCK BALL ASSEMBLY NO.1
(a) Remove the lock ball assembly No.1 from the manual transmission case.





11. REMOVE MANUAL TRANSMISSION BREATHER PLUG
(a) Remove the manual transmission breather plug and gasket.





12. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Remove the shift and select lever shaft assembly from the manual transmission case.





13. REMOVE BACK UP LIGHT SWITCH ASSEMBLY
(a) Remove the back up lamp switch assembly and gasket from the manual transmission case.





14. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket from the manual transmission case.





15. REMOVE DRAIN (MTM) PLUG SUBASSEMBLY
(a) Remove the drain (MTM) plug subassembly and gasket from the manual transmission case.





16. REMOVE MANUAL TRANSMISSION CASE COVER SUBASSEMBLY
(a) Remove the 10 bolts and manual transmission case cover from the manual transmission case.





17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
(a) Double mesh the gears. (Engage 1st and 2nd gears simultaneously.)





(b) Using SST and a hammer, unstake the manual transmission output shaft rear set nut.
SST 09930-00010





(c) Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
SST 09229-55010
(d) Disengage the gears.





18. REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.

HINT: Cover with a shop rag to keep the snap ring from flying.





(b) Remove the shift fork set bolt from the gear shift fork No.3.





(c) Using SST, remove the transmission clutch hub No.3 and gear shift fork No.3 from the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)





19. REMOVE 5TH GEAR
(a) Remove the 5th gear from the input shaft.





20. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing from the input shaft.





21. REMOVE 5TH DRIVEN GEAR
(a) 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





22. REMOVE BEARING RETAINER REAR (MTM)
(a) Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and bearing retainer rear (MTM) from the manual transmission case.





23. REMOVE OUTPUT SHAFT REAR BEARING SHIM
(a) Remove the output shaft rear bearing shim from the output shaft.





24. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
(a) Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.





25. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the gear shift fork shaft No. 1.

HINT: Cover with a shop rag to keep the snap ring from flying.





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

HINT: Cover with a shop rag to keep the snap ring from flying.





26. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and gasket.
27. REMOVE CLUTCH TUBE BRACKET NO.1
(a) Remove the bolt and clutch tube bracket.





28. REMOVE MANUAL TRANSMISSION CASE
(a) Remove the 3 bolts from the manual transaxle case side.





(b) Remove the 14 bolts from the manual transmission case side.
(c) Tapping with a plastic hammer, remove the manual transmission case.





29. REMOVE OIL RECEIVER PIPE NO.2 (MTM)
(a) Remove the bolt and oil receiver pipe No.2 (MTM) from the manual transmission case.

NOTICE: Do not damage the pipe.





30. REMOVE OIL RECEIVER PIPE NO.1 (MTM)
(a) Remove the bolt and oil receiver pipe No.1 (MTM) from the manual transmission case.

NOTICE: Do not damage the pipe.





31. REMOVE REVERSE RESTRICT PIN ASSEMBLY
(a) Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.





(b) Using a pin punch ([diameter]5 mm), remove the slotted pin and reverse restrict pin assembly.





32. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the manual transaxle case.





33. REMOVE REVERSE IDLER GEAR SUBASSEMBLY
(a) Remove the reverse idler gear subassembly from the manual transaxle case.





(b) Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.





34. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case.





35. REMOVE GEAR SHIFT FORK SHAFT NO.1
(a) Remove the shift fork set bolt from the gear shift fork No. 1.





(b) Pull out the gear shift fork shaft No.1 while the gear shift fork shaft No.3 is pulled up.





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

NOTICE: Cover with a shop rag to keep the snap ring from flying.





36. REMOVE REVERSE SHIFT FORK ROLLER
(a) Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.





37. REMOVE GEAR SHIFT FORK SHAFT NO.2
(a) Remove the shift fork set bolt and shift head set bolt from the gear shift fork No.2 and gear shift head No. 1.





(b) Remove the gear shift fork shaft No.2 and gear shift head No.1 from the manual transaxle case.





38. REMOVE GEAR SHIFT FORK NO.1
(a) Remove the gear shift fork No.1.





39. REMOVE GEAR SHIFT FORK SHAFT NO.3
(a) Remove the gear shift fork shaft No.3 from the manual transaxle case.





(b) Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the gear shift fork shaft No. 3.
(c) Remove the reverse shift fork from the gear shift fork shaft No.3.





40. REMOVE GEAR SHIFT FORK NO.2
(a) Remove the gear shift fork No.2 from the input shaft assembly.





41. REMOVE INPUT SHAFT ASSEMBLY
(a) Tilt the output shaft, then remove the input shaft from the manual transaxle case.





42. REMOVE OUTPUT SHAFT ASSEMBLY
(a) Lift the differential case assembly up with the output shaft assembly leaned.
(b) Remove the output shaft assembly from the manual transaxle case.





43. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the differential case assembly from the manual transaxle case.





44. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.





45. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





46. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST, remove the manual transaxle case oil seal from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





47. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.
SST 09387-00041 (09387-02020, 09387-02010)





48. REMOVE OUTPUT SHAFT (MTM) COVER
(a) Remove the output shaft (MTM) cover from the manual transaxle case.





49. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using SST, remove the output shaft rear bearing from the manual transmission case (outer race).
SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)





50. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST, remove the transmission case oil seal from the manual transmission case.
SST 09308-00010





51. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Using a screwdriver, remove the front transaxle case cover oil seal.

HINT: Tape the screwdriver tip before use to avoid damage.





52. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using a brass bar and a hammer, remove the FR differential case front tapered roller bearing (outer race) from the manual transaxle case.





(b) 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)





53. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a hammer, remove the FR differential case rear tapered roller bearing (outer race) and FR differential case rear shim from the manual transmission case.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07100)





(b) Using SST, remove the FR 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)





54. REMOVE TRANSMISSION HUB SLEEVE NO.3
(a) Remove the transmission hub sleeve No.3 from the transmission clutch hub No.3.





55. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3
(a) Remove the 2 synchromesh shifting key springs No.3 from the transmission clutch hub No.3 while pushing on the synchromesh shifting key spring No.3.





56. REMOVE SYNCHRONIZER PULL RING
(a) Using a screwdriver, remove the synchronizer pull ring snap ring.
(b) Remove the synchronizer pull ring, synchronizer outer ring No.5, synchronizer inner ring No.5 and synchronizer ring middle No.5 from the synchronizer ring inner No.5.