Part 1

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

OVERHAUL





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





2. REMOVE DRAIN (MTM) PLUG SUB-ASSY
a. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
3. REMOVE SPEEDOMETER SENSOR (W/O ABS)
a. Remove the bolt and speedometer sensor from the transaxle case.
b. Remove the O-ring from the speedometer sensor.
4. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)
a. Remove the clip and speedometer driven (MTM) gear sub-assy from the speedometer sensor.
5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ ABS)
a. Remove the bolt and speedometer driven hole cover sub-assy from the transaxle case.
b. Remove the O-ring from the speedometer driven hole cover.





6. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork sub-assy with clutch release bearing assy from the transaxle case.





7. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing clip and clutch release bearing assy from the clutch release fork sub-assy.





8. REMOVE RELEASE FORK SUPPORT
a. Remove the clutch release fork support from the transaxle case.





9. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the transaxle case.





10. REMOVE BACK UP LAMP SWITCH ASSY
a. Remove the back up lamp switch assy and gasket from the manual transmission case.





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





12. REMOVE SELECTING BELL CRANK ASSY
a. Remove the 2 bolts and selecting bellcrank assy from the manual transmission case.
b. Remove the control shift lever bush.





13. FIX MANUAL TRANSAXLE ASSY
a. Using 2 wooden blocks, fix the manual transaxle assy.





14. REMOVE LOCK BALL ASSY NO.1
a. Remove the lock ball assy No.1 from the manual transmission case.





15. REMOVE SHIFT & SELECT LEVER SHAFT ASSY
a. Remove the 4 bolts, shift & select lever shaft assy and gasket from the manual transmission case.





16. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY
a. Remove the 9 bolts.





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

NOTICE: Do not damage the manual transmission case.





17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.





b. Engage the gear to the double meshing.
c. Remove the manual transmission output shaft rear set nut.
d. Disengage the double mashing of the gear.





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





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





19. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 5th gear thrust clearance.





5th gear thrust clearance





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





5th gear radial clearance

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





21. REMOVE TRANSMISSION CLUTCH HUB NO.3
a. Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: Using a waste to prevent the snap ring from being scattered.





b. Using SST, remove the transmission clutch hub No.3, 5th gear and synchronizer ring No.3 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 transmission clutch hub No.3.





22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
a. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.





23. 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)





24. REMOVE BEARING RETAINER REAR (MTM)
a. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.





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





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





27. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.





28. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No.2.

HINT: Using a waste to prevent the snap ring from being scattered.





29. REMOVE SHIFT DETENT BALL
a. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.





b. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.





c. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.





d. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.





30. REMOVE LOCK BALL ASSY NO.1
a. Using a hexagon wench, remove the lock ball assy No.1 from the manual transmission case.





31. REMOVE MANUAL TRANSMISSION CASE
a. Remove the 3 bolts from the transaxle case side.





b. Remove the 13 bolts from the manual transmission case side.





c. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.

NOTICE: Do not damage the manual transmission case and transaxle case.





32. REMOVE REVERSE IDLER GEAR SUB-ASSY
a. Remove the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft from the transaxle case.