Part 1

MANUAL TRANSAXLE ASSEMBLY (C50)
OVERHAUL





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





2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY
a. Remove the drain plug and gasket from the manual transmission case.





3. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY
a. Remove the 2 bolts and clutch release cylinder assembly.
4. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a. Remove the bolt and speedometer driven hole cover sub-assembly.
b. Remove the O-ring from the speedometer driven hole cover sub-assembly.





5. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Remove the clutch release fork sub-assembly with clutch release bearing assembly from the front transaxle case.





6. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a. Remove the clutch release fork bearing hub clip and clutch release bearing assembly from the clutch release fork sub-assembly.





7. REMOVE RELEASE FORK SUPPORT
a. Remove the clutch release fork support from the front transaxle case.





8. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the front transaxle case.





9. REMOVE BACK UP LAMP SWITCH ASSEMBLY
a. Using SST, remove the back-up lamp switch assembly and gasket from the manual transmission case.
SST 09817-16011





10. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Remove the 3 bolts and control lever housing support bracket from the front transaxle case.





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





12. FIX MANUAL TRANSAXLE ASSEMBLY
a. Using 2 wooden blocks, fix the manual transaxle assembly.





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





14. REMOVE SHIFT & SELECT LEVER SHAFT ASSEMBLY
a. Remove the 4 bolts, shift & select lever shaft assembly and gasket from the manual transmission case.





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





b. Gently tap the protrusion of the manual transmission case cover sub-assembly with a hammer and remove it.

NOTICE: Be careful not to 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 two gears simultaneously to lock the transmission.
c. Remove the manual transmission output shaft rear set nut.
d. Disengage the two gears.





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





b. Remove the hub sleeve No.3 and gear shift fork No.3 from the transmission clutch hub No.3.





18. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.02244 in.)
Maximum clearance: 0.57 mm (0.02244 in.)





19. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 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 gear,needle roller bearing or 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 to keep the snap ring from flying.





b. Using SST, remove the transmission clutch hub No.3, 5th gear and synchronizer ring No.3 from the input shaft.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200)





c. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No.3.





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, 09955-03011, 09957-04010), 09950-60010 (09951-00190)





23. REMOVE BEARING RETAINER REAR (MTM)
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.