Part 1

Transmission Disassemble




1. Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.
2. Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.




3. Remove the release fork support (1) from the manual transaxle case.
4. Remove the clutch release fork boot from the manual transaxle case.
5. Remove the bolt and speedometer driven hole cover sub-assembly.
6. Remove the O-ring.




7. Remove the bolts (1, 2) and selecting bellcrank assembly from the manual transmission case.




8. Remove the nut (1) and spring washer.




9. Remove the nut and spring washer.
10. Remove the control shift lever.




11. Remove the bolts (1) and control shaft cover from the manual transmission case.




12. Remove the bolt and No. 2 clutch tube bracket (1).




13. Place the manual transaxle assembly on wooden blocks.




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




15. Remove the shift gate pin (1) from the manual transmission case.




16. Remove the manual transmission breather plug (1).




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




18. Remove the back-up light switch assembly (1) and gasket from the manual transmission case.




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




20. Remove the drain plug (1) and gasket from the manual transmission case.




21. Remove the bolts (1-10) and manual transmission case cover from the manual transmission case.




22. Engage the 1st and 2nd gears (1) simultaneously.




23. Using a punch (1) and a hammer, unstake the manual transmission output shaft rear set nut.




24. Remove the manual transmission output shaft rear set nut (1) from the output shaft.
25. Disengage the gears.




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




27. Remove the shift fork set bolt (1) from the No. 3 gear shift fork.




28. Using a suitable puller (1), remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft.




29. Remove the 5th gear from the input shaft.




30. Remove the 5th gear needle roller bearing from the input shaft.




31. Using a suitable puller (1), remove the 5th driven gear from the output shaft.




32. Remove the bolts (1-7) and rear bearing retainer from the manual transmission case.




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




34. Remove the input shaft rear bearing shaft snap ring from the input shaft.




35. Remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.




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




37. Remove the reverse idler gear shaft bolt (1) and gasket.




38. Remove the bolts (1-3) from the manual transaxle case.




39. Remove the bolts (1-14) from the manual transmission case.
40. Tapping with a plastic hammer, remove the manual transmission case.




41. Remove the reverse restrict pin plug (1) from the manual transmission case.




42. Using a pin punch and hammer, remove the slotted pin.




43. Remove the bolt (1), transmission oil baffle and reverse restrict pin assembly.




44. Remove the bolt (1) and No. 2 oil receiver pipe from the manual transmission case.




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




46. Remove the transmission magnet from the manual transaxle case.




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




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




49. Remove the bolts (1) and reverse shift arm bracket assembly from the manual transaxle case.




50. Remove the shift fork set bolt (1) from the No. 1 gear shift fork.




51. Pull out the No. 1 gear shift fork shaft (1) while pulling up the No. 3 gear shift fork shaft.




52. Remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.




53. Using a magnetic pick-up tool, remove the reverse shift fork roller from the reverse shift fork.




54. Remove the shift fork set bolt (1) and shift head set bolt (2) from the No. 2 gear shift fork and No. 1 gear shift head.




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