Part 2

E350 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REMOVAL - (Continued)

31. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket.

32. REMOVE MANUAL TRANSMISSION CASE

(a) Remove the 3 bolts from the transaxle case side.

(b) Remove the 14 bolts from the transmission case side.

(c) Tapping with a plastic-faced hammer, remove the transmission case.

33. REMOVE REVERSE RESTRICT PIN ASSEMBLY

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

(b) Using a pin punch (5 mm), remove the slotted pin.

34. REMOVE NO. 2 OIL RECEIVER PIPE

(a) Remove the bolt and No. 2 oil receiver pipe from the transmission case.

NOTICE:

Do not damage the pipe.

35. REMOVE NO. 1 OIL RECEIVER PIPE

(a) Remove the bolt and oil receiver pipe from the transmission case.

NOTICE:

Do not damage the pipe.

36. REMOVE TRANSMISSION MAGNET

(a) Remove the transmission magnet from the transaxle case.

37. 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.

38. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Remove the 2 bolts and reverse shift arm bracket from the transaxle case.

39. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

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

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

HINT

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

40. REMOVE REVERSE SHIFT FORK ROLLER

(a) Using a magnet hand, remove the reverse shift fork roller from the reverse shift fork.

41. 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.

42. REMOVE NO. 1 GEAR SHIFT FORK

(a) Remove the No. 1 gear shift fork.

43. 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

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

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

44. REMOVE NO. 2 GEAR SHIFT FORK

(a) Remove the No. 2 gear shift fork from the input shaft.

45. REMOVE INPUT SHAFT ASSEMBLY

(a) Tilt the output shaft, then remove the input shaft from the transaxle case.

46. REMOVE OUTPUT SHAFT ASSEMBLY

(a) Slightly lift up the differential case with the output shaft at an angle.

(b) Remove the output shaft from the transaxle case.

47. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the differential case from the transaxle case.

48. REMOVE MANUAL TRANSAXLE CASE RECEIVER

(a) Remove the 3 bolts and transaxle case receiver from the transaxle case.

49. 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

50. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL

(a) Using SST, remove the oil seal from the transaxle case.

SST : 09612-65014

09612-01040

09612-01050

51. REMOVE OUTPUT SHAFT FRONT BEARING OUTER RACE

(a) Using SST, remove the front bearing outer race from the transaxle case.

SST : 09387-00041

SST : 09387-02010

SST : 09387-02020

52. REMOVE OUTPUT SHAFT COVER

(a) Remove the output shaft cover from the transaxle case.

53. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE

(a) Using SST, tap out the rear bearing outer race from the transmission case outer race.

SST : 09950-60010

09951-00680

SST : 09950-70010

09951-07100

54. REMOVE TRANSMISSION CASE OIL SEAL

(a) Using SST, tap out the oil seal from the transmission case.

SST : 09308-00010

55. REMOVE FRONT TRANSAXLE CASE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.

HINT

Tape the screwdriver tip before use to avoid damage.

56. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

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

SST : 09308-00010

(b) Remove the front differential oil baffle.

(c) Using SST, remove the 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

57. 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 from the front differential case.

SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00490

58. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Using a caliper gauge, measure the inside diameter of the reverse idler gear.

Standard inside diameter:

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

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

Standard outside diameter:

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

59. REMOVE NO. 3 TRANSMISSION HUB SLEEVE

(a) Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.

60. 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.

61. 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.

62. 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.

63. 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.)

(b) If the clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones.

64. INSPECT 5TH GEAR

(a) Using a caliper gauge, measure the inside diameter of the 5th gear.

Standard inside diameter:

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