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Part 1





E350 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REMOVAL

1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Remove the clutch release fork with the clutch release bearing from the transaxle case.





2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

(a) Remove the release bearing and clutch release bearing hub clip from the clutch release fork.

3. INSTALL RELEASE FORK SUPPORT

(a) Remove the release fork support from the transaxle case.





4. REMOVE CLUTCH RELEASE FORK BOOT

(a) Remove the clutch release fork boot from the manual transaxle case.

5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

(a) Remove the bolt and hole cover.

(b) Remove the O-ring from the hole cover.

6. REMOVE CONTROL CABLE BRACKET

(a) Remove the 3 bolts and control cable bracket.





7. REMOVE SELECTING BELLCRANK ASSEMBLY

(a) Remove the 2 bolts and selecting bellcrank assembly from the transmission case.





(b) Remove the shift and select lever bushing from the selecting bellcrank.

8. REMOVE CONTROL SHIFT LEVER

(a) Remove the nut and spring washer.





(b) Using a brass bar and a hammer, remove the shift outer lever lock pin.





(c) Remove the control shift lever.

9. REMOVE CONTROL SHAFT COVER

(a) Remove the 4 bolts, control shaft cover and gasket from the transmission case.





10. REMOVE CLUTCH TUBE BRACKET

(a) Remove the bolt and clutch tube bracket.





11. SECURE MANUAL TRANSAXLE ASSEMBLY

(a) Place the transaxle on wooden blocks.





12. REMOVE NO. 1 LOCK BALL ASSEMBLY

(a) Remove the No. 1 lock ball assembly from the manual transmission case.





13. REMOVE SHIFT GATE PIN

(a) Remove the shift gate pin and gasket from the manual transmission case.





14. REMOVE MANUAL TRANSMISSION BREATHER PLUG

(a) Remove the manual transmission breather plug.





15. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the shift and select lever shaft from the transmission case.





16. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Remove the back-up light switch and gasket from the transmission case.





17. REMOVE MANUAL TRANSMISSION FILLER PLUG

(a) Remove the manual transmission filler plug and gasket from the transmission case.





18. REMOVE DRAIN PLUG SUB-ASSEMBLY

(a) Remove the drain plug and gasket from the transmission case.





19. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY

(a) Remove the 10 bolts and transmission case cover from the transmission case.





20. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT

(a) Engage the 2 gears simultaneously to lock the transmission.





(b) Using SST and a hammer, unstake the manual transmission output shaft rear set nut.





SST : 09930-00010

(c) Using a socket wrench 30 mm, remove the manual transmission output shaft rear set nut from the output shaft.





(d) Disengage the 2 gears.

21. 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 in.)

(b) If the clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

22. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance.





Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

(b) If the clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

23. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

(a) Using 2 screwdrivers and a hammer, remove the No. 3 transmission clutch hub shaft snap ring from the input shaft.





HINT

Use a piece of cloth to keep the snap ring from flying off.

(b) Remove the shift fork set bolt from the No. 3 gear shift fork.





(c) Using SST, remove the No. 3 transmission clutch hub, No. 3 transmission hub sleeve and No. 3 gear shift fork from the input shaft.





SST : 09950-30012

09951-03010

09953-03010

09954-03010

SST : 09950-50013

09957-04010

SST : 09950-60010

09951-00280

24. REMOVE 5TH GEAR

(a) Remove the 5th gear from the input shaft.





25. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the input shaft.





26. 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

09957-04010

SST : 09950-60010

09951-00180

09955-03011

SST : 09950-50013

27. REMOVE REAR BEARING RETAINER

(a) Using a T45 "TORX" socket, remove the 7 "TORX" screws and bearing retainer from the transmission case.





28. REMOVE OUTPUT SHAFT REAR BEARING SHIM

(a) Remove the rear bearing shim from the output shaft.





29. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING

(a) Using a snap ring expander, remove the shaft snap ring from the input shaft.





30. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 1 gear shift fork shaft.





HINT

Use a piece of cloth to keep the snap ring from flying off.

(b) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 gear shift fork shaft.





HINT

Use a piece of cloth to keep the snap ring from flying off.
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