Part 2
MANUAL TRANSAXLE UNITDISASSEMBLY (STEPS 27-52)
27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.
NOTICE: Use a cloth to keep the snap ring from springing away.
28. REMOVE SHIFT DETENT BALL
a. Using a hexagon wrench, remove the 2 shift detent ball plugs from the transmission case.
b. Using a magnetic finger, remove the 2 No. 1 shift detent ball spring seats, 2 shift detent ball springs and 2 shift detent balls from the transmission case.
c. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
d. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
29. REMOVE NO. 2 LOCK BALL ASSEMBLY
a. Using a hexagon wrench, remove the No. 2 lock ball from the transmission case.
30. REMOVE MANUAL TRANSMISSION CASE
a. Remove the 3 bolts from the front transaxle case.
b. Remove the 13 bolts from the transmission case.
c. Using a brass bar and hammer, carefully tap the projection of the transmission case to remove it from the transaxle case.
NOTICE: Do not damage the transmission case and transaxle case.
31. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
a. Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.
32. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
a. Remove the 2 bolts and reverse shift arm bracket from the front transaxle case.
33. REMOVE NO. 2 GEAR SHIFT FORK SHAFT
a. Remove the 2 bolts from the No. 2 gear shift fork and No. 1 gear shift head.
b. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the front transaxle case.
34. REMOVE NO. 1 GEAR SHIFT FORK SHAFT
a. Using 2 screwdrivers and a hammer, tap out the snap ring.
NOTICE: Use a cloth to keep the snap ring from springing away.
b. Remove the shift fork set bolt and No. 1 gear shift fork shaft from the No. 1 gear shift fork.
c. Remove the No. 1 gear shift fork.
35. REMOVE NO. 3 GEAR SHIFT FORK SHAFT
a. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
NOTICE: Use a cloth to keep the snap ring from springing away.
b. Remove the No. 3 gear shift fork shaft with reverse shift fork and No. 2 gear shift fork from the transaxle case.
c. Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
d. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 shift fork shaft.
NOTICE: Use a cloth to keep the snap ring from springing away.
e. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
36. REMOVE INPUT SHAFT ASSEMBLY
a. Remove the input shaft and output shaft from the front transaxle case.
37. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Remove the differential case from the front transaxle case.
38. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the bolt and transaxle case receiver from the front transaxle case.
39. REMOVE REVERSE RESTRICT PIN ASSEMBLY
a. Using a hexagon wrench, remove the reverse restrict pin plug from the transmission case.
b. Using a 5 mm pin punch and hammer, tap out the slotted spring pin and remove the reverse restrict pin from the transmission case.
40. REMOVE NO. 1 OIL RECEIVER PIPE
a. Remove the bolt and No. 1 oil receiver pipe from the transmission case.
NOTICE: Be careful not to damage the No. 1 oil receiver pipe.
41. REMOVE NO. 2 OIL RECEIVER PIPE
a. Remove the bolt and No. 2 oil receiver pipe from the transmission case.
NOTICE: Be careful not to damage the No. 2 oil receiver pipe.
42. REMOVE BEARING LOCK PLATE
a. Remove the bolt and bearing lock plate from the front transaxle case.
43. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the front transaxle case.
44. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST, remove the front bearing from the front transaxle case.
SST 09612-65014 (09612-01050, 09612-01060)
45. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using a screwdriver, pry out the front transaxle case oil seal from the transaxle case.
46. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the front bearing from the front transaxle case.
SST 09308-00010
NOTICE: Do not apply excessive force to the front transaxle case when installing it.
47. REMOVE OUTPUT SHAFT COVER
a. Remove the output shaft cover from the front transaxle case.
48. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)
NOTICE: Be careful not to damage the bearing.
49. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, tap out the transaxle case oil seal from the front transaxle case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
50. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the rear tapered roller bearing (outer race) and plate washer from the transmission case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
NOTICE: Be careful not to damage the bearing.
51. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, tap out the transmission case oil seal from the transmission case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
52. REMOVE SHIFT AND SELECT LEVER SHAFT BIMETAL FORMED BUSH
a. Using SST, remove the bush.
SST 09319-60020