Part 2

51. 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.




52. Remove the reverse idler gear sub-assembly, thrust washer, and reverse idler gear shaft from the transaxle case.




53. Remove the bolts (1, 2) and reverse shift arm bracket assembly from the transaxle case.




54. Remove the bolts (1, 2) from the No. 2 gear shift fork and No. 1 gear shift head.




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





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

56. Using 2 screwdrivers and a hammer, tap out the snap ring.




57. Remove the shift fork set bolt (2) and No. 1 gear shift fork shaft (1) from the No. 1 gear shift fork.




58. Remove the No. 1 gear shift fork (1).





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

59. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.




60. Remove the No. 3 gear shift fork shaft (1) together with the reverse shift fork and No. 2 gear shift fork from the manual transaxle case.




61. Using a magnetic pick-up tool, remove the reverse shift fork balls from the reverse shift fork.





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

62. Using 2 screwdrivers and a hammer, tap the snap ring out of the No. 3 shift fork shaft.
63. Remove the reverse shift fork from the No. 3 gear shift fork shaft.




64. Remove the input shaft assembly and output shaft assembly from the transaxle case.




65. Remove the differential case assembly from the transaxle case.




66. Remove the bolt (1) and manual transaxle case receiver from the transaxle case.




67. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.




68. Using a pin punch (5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.





Note: Do not damage the No. 1 oil receiver pipe.

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





Note: Do not damage the No. 2 oil receiver pipe.

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




71. Remove the bolt (1) and bearing lock plate from the transaxle case.




72. Remove the transmission magnet from the transaxle case.
73. Remove the input shaft front bearing from the transaxle case.




74. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
75. Remove the output shaft front bearing from the transaxle case.




76. Remove the output shaft cover from the transaxle case.




77. Using a suitable puller (1), remove the front differential case front tapered roller bearing (outer race) and plate washer from the transaxle case.




78. Using a suitable puller (4), remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.




79. Using a suitable driver (1) and a hammer, remove the transaxle case oil seal from the transaxle case.
80. Remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
81. Remove the front differential case rear tapered roller bearing (inner race) from the front differential case.




82. Using a suitable driver (2) and a hammer, drive out the transmission case oil seal from the manual transmission case.




83. Using a screwdriver and a hammer, remove the shift and select lever shaft oil seal.




84. Using a suitable driver (1) and a plastic hammer, remove the shift and select lever shaft slide ball bearing.




85. Inspect the No. 3 synchronizer ring. Check for wear and damage.
86. Coat the 5th gear cone with gear oil.
87. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone.
88. Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring.




89. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

* Standard clearance - 0.75-1.65 mm (0.0295-0.0249 in)
* Maximum clearance - 0.75 mm (0.0295 in)

90. If the clearance is less than the minimum, replace the synchronizer ring.




91. Check the sliding condition between the No. 3 transmission hub sleeve and the No. 3 transmission clutch hub.
92. Check that the edges of the No. 3 transmission hub sleeve spline gear are not worn down.




93. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 gear shift fork (B), and calculate the clearance.

Standard Clearance (A-B) 0.3-0.5 mm (0.0118-0.0197 in)

94. If the clearance exceeds the standard, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.




95. Inspect the 5th gear. Using a caliper gage, measure the inside diameter.

* Standard inside diameter - 29.915-29.931 mm (1.1778-1.1783 in)
* Maximum inside diameter - 29.931 mm (1.1783 in)

96. If the inside diameter exceeds the maximum, replace the 5th gear.




97. Using a feeler gage, measure the 4th gear thrust clearance.

* Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)
* Maximum clearance - 0.55 mm (0.0217 in)

98. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.




99. Using a dial indicator, measure the 3rd gear thrust clearance.

* Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)
* Maximum clearance - 0.35 mm (0.0138 in)

100. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.




101. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

* Standard clearance, NSK made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Standard clearance, KOYO made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Maximum clearance, NSK made bearing - 0.050 mm (0.0019 in)
* Maximum clearance, KOYO made bearing - 0.050 mm (0.0019 in)

102. If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.




103. Using a dial indicator, measure the 3rd gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

104. If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.





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