Part 2
31. 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.
32. 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.
33. 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 (5 mm), remove the reverse restrict pin slotted spring pin.
c. Remove the reverse restrict pin assembly.
34. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the manual transaxle case.
35. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
a. Remove the reverse idler gear sub-assembly with the reverse idler gear shaft from the manual transaxle case.
b. Remove the reverse idler gear sub-assembly and reverse idler thrust washer from the reverse idler gear shaft.
36. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
a. Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case.
37. 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.
HINT: Cover with a shop rag to keep the snap ring from flying.
38. REMOVE REVERSE SHIFT FORK ROLLER
a. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
39. 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.
40. REMOVE GEAR SHIFT FORK NO.1
a. Remove the gear shift fork No.1.
41. 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.
42. REMOVE GEAR SHIFT FORK NO.2
a. Remove the gear shift fork No.2 from the input shaft assembly.
43. REMOVE INPUT SHAFT ASSEMBLY
a. Tilt the output shaft, then remove the input shaft from the manual transaxle case.
44. REMOVE OUTPUT SHAFT ASSEMBLY
a. Slightly lift up on the differential case assembly with the output shaft assembly at an angle.
b. Remove the output shaft assembly from the manual transaxle case.
45. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Remove the differential case assembly from the manual transaxle case.
46. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
47. 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)
48. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using SST, remove the front transaxle case oil seal from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
49. 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)
50. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output shaft (MTM) cover from the manual transaxle case.
51. 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)
52. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST, remove the transmission case oil seal from the manual transmission case.
SST 09308-00010
53. 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.
54. 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 FR differential case front tapered roller bearing from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560)
55. 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 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490)
56. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
a. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
Inside diameter: mm (in.)
If the inside diameter exceeds the maximum, replace the reverse idler gear.
b. Using a micrometer, measure the outside diameter of the reverse idler gear shaft.
Outside diameter: mm (in.)
If the outside diameter is less than the minimum, replace the reverse idler gear shaft.
57. REMOVE TRANSMISSION HUB SLEEVE NO.3
a. Remove the transmission hub sleeve No.3 from the transmission clutch hub No.3.
58. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3
a. Remove the 2 synchromesh shifting key springs No.3 and synchronizer ring set from the transmission clutch hub No.3 while pushing on the synchromesh shifting key spring No.3.
59. REMOVE SYNCHRONIZER PULL RING
a. Using a screwdriver, remove the synchronizer pull ring snap ring.
b. Remove the synchronizer pull ring, synchronizer ring outer No.5, synchronizer ring inner No.5 and synchronizer ring middle No.5.
60. INSPECT TRANSMISSION CLUTCH HUB NO.3
a. Inspect the sliding condition between the transmission clutch hub No.3 and the transmission hub sleeve No.3.
b. Inspect the tip of the spline gear on the transmission hub sleeve No.3 for wear.