Part 1

DISASSEMBLY

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

2. REMOVE DRAIN PLUG SUB-ASSEMBLY
(a) Remove the drain plug sub-assembly and gasket from the manual transmission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
(b) Remove the O-ring from the speedometer driven hole cover sub-assembly.
4. REMOVE SPEEDOMETER SENSOR (w/o ABS)
(a) Remove the bolt and speedometer sensor from the transaxle case.

5. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
(a) Separate the back-up light switch wire harness from the 2 clamps.
(b) Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.
SST 09817-16011

6. REMOVE SELECTING BELL CRANK ASSEMBLY
(a) Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.
(b) Remove the control shift lever bush.

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

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

8. REMOVE SHIFT LEVER DAMPER
(a) Remove the nut and spring washer.

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

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

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

11. REMOVE SHIFT GATE PIN
(a) Remove the shift gate pin and washer from the transmission case.

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

13. REMOVE CONTROL SHAFT COVER OIL SEAL
(a) Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.

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

15. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
(a) Remove the 9 bolts.

(b) Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.

NOTICE: Do not damage the manual transmission case.

16. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
(a) Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.

(b) Engage the 2 gears simultaneously to lock the transmission.
(c) Remove the manual transmission output shaft rear set nut.
(d) Disengage the 2 gears.

17. REMOVE GEAR SHIFT FORK NO.3
(a) Remove the gear shift fork lock bolt from gear shift fork No. 3.

(b) Remove transmission hub sleeve No. 3 with gear shift fork No. 3 from transmission clutch hub No. 3.

18. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance: 0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace transmission clutch hub No. 3, the 5th gear or input shaft rear radial ball bearing.

19. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance:
KOYO made: 0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made: 0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 in.)
NSK made: 0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

20. REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: Use a shop rag or piece of cloth to keep the snap ring from flying off.

(b) Using SST, remove transmission clutch hub No. 3, the 5th gear and synchronizer ring No. 3 from the input shaft.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04011), 09950-60010 (09951-00180)

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

22. 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, 09955-03021), 09950-60010 (09951-00180)

23. REMOVE BEARING RETAINER REAR
(a) Remove the 5 bolts and bearing retainer rear from the manual transmission case.

24. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
(a) Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.

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