Part 1

MANUAL TRANSAXLE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 1-26)

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

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

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

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

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

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 LIGHT SWITCH ASSEMBLY
a) Using SST, remove the back-up light switch and gasket from the transmission case.
SST 09817-16011

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

11. REMOVE SELECTING BELLCRANK ASSEMBLY
a) Remove the 2 bolts and selecting bellcrank from the transmission case.
b) Remove the control shift lever bush.

12. FIX MANUAL TRANSAXLE ASSEMBLY
a) Place the transaxle on wooden blocks.

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

14. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a) Remove the 4 bolts, lever shaft and gasket from the transmission case.

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

b) Using a plastic-faced hammer, carefully tap the projection of the manual transmission case cover to remove it from the transmission case.

NOTICE: Do not damage the transmission case.

16. REMOVE MANUAL TRANSMISSION REAR OUTPUT SHAFT SET NUT
a) Using a chisel and hammer, loosen the staked part of the set nut.

b) Engage the 2 gears simultaneously to lock the transmission.
c) Remove the transmission output shaft rear set nut.
d) Disengage the 2 gears.

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

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

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 0.0224 inch)
Maximum clearance: 0.57 mm (0.0224 inch)
If the clearance is greater than the maximum, replace the 5th gear needle roller bearing or input shaft.

19. INSPECT 5TH GEAR RADIAL CLEARANCE
a) Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance

Standard clearance:

Maximum clearance

Maximum clearance:

If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.

20. REMOVE NO. 3 TRANSMISSION CLUTCH HUB
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) Using SST, remove the No. 3 transmission clutch hub, 5th gear and No. 3 synchronizer ring 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 No. 3 transmission clutch hub.

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 REAR BEARING RETAINER
a) Remove the 5 bolts and bearing retainer from the manual transmission case.

24. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a) Using a snap ring expander, remove the hole snap ring from the output shaft.

25. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
a) Using a snap ring expander, remove the hole snap ring from the input shaft.

26. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a) Remove the shaft bolt and gasket from the transmission case.