Part 2

E350 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REMOVAL - Continued


32. REMOVE NO. 1 OIL RECEIVER PIPE
(a) Remove the bolt and oil receiver pipe from the transmission case.
NOTE: Do not damage the pipe.

33. REMOVE REVERSE RESTRICT PIN ASSEMBLY





(a) Using a 6 mm hexagon wrench, remove the reverse restrict pin plug from the transmission case.






(b) Using a 5 mm pin punch, remove the slotted pin.
(c) Remove the reverse restrict pin.






34. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the transaxle case.
35. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY





(a) Remove the reverse idler gear with the reverse idler gear shaft from the transaxle case.






(b) Remove the reverse idler gear and reverse idler thrust washer from the gear shaft.






36. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Remove the 2 bolts and reverse shift arm bracket from the transaxle case.
37. REMOVE NO. 1 GEAR SHIFT FORK SHAFT





(a) Remove the shift fork set bolt from the No. 1 gear shift fork.






(b) Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shift is pulled up.






(c) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.





38. REMOVE REVERSE SHIFT FORK ROLLER
(a) Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
39. REMOVE NO. 2 GEAR SHIFT FORK SHAFT





(a) Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.






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






40. REMOVE NO. 1 GEAR SHIFT FORK
41. REMOVE NO. 3 GEAR SHIFT FORK SHAFT





(a) Remove the No. 3 gear shift fork shaft from the transaxle case.






(b) Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.

(c) Remove the reverse shift fork from the No. 3 gear shift fork shaft.






42. REMOVE NO. 2 GEAR SHIFT FORK
(a) Remove the No. 2 gear shift fork from the input shaft.






43. REMOVE INPUT SHAFT ASSEMBLY
(a) Tilt the output shaft, then remove the input shaft from the transaxle case.






44. REMOVE OUTPUT SHAFT ASSEMBLY
(a) Slightly lift up on the differential case with the output shaft at an angle.
(b) Remove the output shaft from the transaxle case.






45. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the differential case from the transaxle case.






46. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the 3 bolts and transaxle case receiver from the transaxle case.






47. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST, remove the input shaft front bearing (outer race) from the transaxle case.
SST: 09612-65014
09612-01040
09612-01050






48. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST, remove the oil seal from the transaxle case.
SST: 09612-65014
09612-01040
09612-01050






49. REMOVE FRONT OUTPUT SHAFT BEARING
(a) Using SST, remove the front bearing (outer race) from the transaxle case.






50. REMOVE OUTPUT SHAFT COVER
(a) Remove the output shaft cover from the transaxle case.






51. REMOVE REAR OUTPUT SHAFT BEARING
(a) Using SST, tap out the rear bearing from the transmission case (outer race).
SST: 09950-60010
09951-00680
SST: 09950-70010
09951-07100






52. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST, tap out the oil seal from the transmission case.
SST: 09308-00010






53. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Using a screwdriver, pry out the cover oil seal.
HINT: Tape the screwdriver tip before use to avoid damage.

54. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING





(a) Using a brass bar and hammer, tap out the front tapered roller bearing (outer race) from the transaxle case.






(b) Using SST, remove the case front tapered roller bearing from the front differential case.
SST: 09950-00020
SST: 09950-00030
SST: 09950-40011
09957-04010
SST: 09950-60010
09951-00560
55. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING





(a) Using SST and a hammer, tap out the rear tapered roller bearing (outer race) and rear shim from the transmission case.
SST: 09950-60020
09951-00790
SST: 09950-70010
09951-07100






(b) Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.
SST: 09950-00020
SST: 09950-00030
SST: 09950-40011
09957-04010
SST: 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.
Standard inside diameter:





If the inside diameter is greater than the maximum, replace the reverse idler gear.






(b) Using a micrometer, measure the outside diameter of the reverse idler gear shaft.
Standard outside diameter:





If the outside diameter is less than the minimum, replace the reverse idler gear shaft.






57. REMOVE NO. 3 TRANSMISSION HUB SLEEVE
(a) Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.






58. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING
(a) Remove the 2 No. 3 synchromesh shifting key springs and synchronizer ring set from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.






59. REMOVE SYNCHRONIZER PULL RING
(a) Using a screwdriver, remove the synchronizer pull ring snap ring.
(b) Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner and No. 5 synchronizer ring middle.






60. INSPECT NO. 3 TRANSMISSION CLUTCH HUB
(a) Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve.
(b) Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear.






61. INSPECT NO. 3 TRANSMISSION HUB SLEEVE
(a) 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 = 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones.






62. INSPECT 5TH GEAR
(a) Using a caliper gauge, measure the inside diameter of the 5th gear.
Standard inside diameter:





If the inside diameter is greater the maximum, replace the 5th gear.