Part 2 of 4
MANUAL TRANSAXLE ASSY
OVERHAUL
35. REMOVE REVERSE IDLER GEAR SUB-ASSY
a) Remove the reverse idler gear sub-assy from the manual transaxle case.
b) Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
36. REMOVE REVERSE SHIFT ARM BRACKET ASSY
a) Remove the 2 bolts and reverse shift arm bracket assy from the manual transaxle case.
37. REMOVE GEAR SHIFT FORK SHAFT NO.1
a) Remove the shift fork set bolt from the gear shift fork No. 1.
b) Pull out the gear shift fork shaft No.1 while the gear shift fork shaft No.3 is pulled up.
c) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.1.
NOTICE: Cover with a shop rag to keep the snap ring from flying.
38. REMOVE REVERSE SHIFT FORK ROLLER
a) Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
39. REMOVE GEAR SHIFT FORK SHAFT NO.2
a) Remove the shift fork set bolt and shift head set bolt from the gear shift fork No.2 and gear shift head No.1.
b) Remove the gear shift fork shaft No.2 and gear shift head No.1 from the manual transaxle case.
40. REMOVE GEAR SHIFT FORK NO.1
41. REMOVE GEAR SHIFT FORK SHAFT NO.3
a) Remove the gear shift fork shaft No.3 from the manual transaxle case.
b) Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the gear shift fork shaft No. 3.
c) Remove the reverse shift fork from the gear shift fork shaft No.3.
42. REMOVE GEAR SHIFT FORK NO.2
a) Remove the gear shift fork No.2 from the input shaft assy.
43. REMOVE INPUT SHAFT ASSY
a) Tilt the output shaft, then remove the input shaft from the manual transaxle case.
44. REMOVE OUTPUT SHAFT ASSY
a) Lift the differential case assy up with the output shaft assy leaned.
b) Remove the output shaft assy from the manual transaxle case.
45. REMOVE DIFFERENTIAL CASE ASSY
a) Remove the differential case assy from the manual transaxle case.
46. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a) Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
47. REMOVE INPUT SHAFT FRONT BEARING
a) Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
48. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a) Using SST, remove the manual transaxle case oil seal from the manual transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
49. REMOVE OUTPUT SHAFT FRONT BEARING
a) Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.
SST 09387-00040 (09387-02020, 09387-02010)
50. REMOVE OUTPUT SHAFT (MTM) COVER
a) Remove the output shaft (MTM) cover from the manual transaxle case.
51. REMOVE OUTPUT SHAFT REAR BEARING
a) Using SST, remove the output shaft rear bearing from the manual transmission case (outer race).
SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)
52. REMOVE TRANSMISSION CASE OIL SEAL
a) Using SST, remove the transmission case oil seal from the manual transmission case.
SST 09308-00010
53. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL
a) Using a screwdriver, remove the front transaxle case cover oil seal.
HINT: Tape the screwdriver tip before use to avoid damage.
54. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a) Using a brass bar and a hammer, remove the FR differential case front tapered roller bearing (outer race) from the manual transaxle case.
b) Using SST, remove the front differential case front tapered roller bearing from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560)
55. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a) Using SST and a hammer, remove the FR differential case rear tapered roller bearing (outer race) and FR differential case rear shim from the manual transmission case.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07100)
b) Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490)
56. INSPECT REVERSE IDLER GEAR SUB-ASSY
a) Using a caliper gauge, measure the inside diameter of the reverse idler gear.
Inside diameter
If the inside diameter exceeds the maximum, replace the reverse idler gear.
b) Using a micrometer, measure the outside diameter of the reverse idler gear shaft.
Outside diameter
If the outside diameter is less than the minimum, replace the reverse idler gear shaft.
57. REMOVE TRANSMISSION HUB SLEEVE NO.3
a) Remove the transmission hub sleeve No.3 from the transmission clutch hub No.3.
58. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3
a) Remove the 2 synchromesh shifting key springs No.3 from the transmission clutch hub No.3 while pushing on the synchromesh shifting key spring No.3.
59. REMOVE SYNCHRONIZER PULL RING
a) Using a screwdriver, remove the synchronizer pull ring snap ring.
b) Remove the synchronizer pull ring, synchronizer outer ring No.5, synchronizer inner ring No.5 and synchronizer ring middle No.5 from the synchronizer ring inner No.5.
60. INSPECT TRANSMISSION CLUTCH HUB NO.3
a) Inspect the sliding condition between the transmission clutch hub No.3 and the transmission hub sleeve No.3.
b) Inspect the tip of the spline gear on the transmission hub sleeve No.3 for wear.
61. INSPECT TRANSMISSION HUB SLEEVE NO.3
a) Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove and the thickness of the claw part on the gear shift fork No.3, and calculate the clearance.
Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch) {A - B}
If clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3 with new ones.
62. INSPECT 5TH GEAR
a) Using a caliper gauge, measure the inside diameter of the 5th gear.
Inside diameter
If the inside diameter exceeds the maximum, replace the 5th gear.
63. INSTALL SYNCHRONIZER PULL RING
a) Install the synchronizer middle ring No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchronizer ring inner No. 5. Using a screwdriver, fix them with the snap ring.
64. INSPECT SYNCHRONIZER RING MIDDLE NO.5
a) Check that the synchronizer ring middle No.5 rotates smoothly.
b) Check that the synchronizer ring middle No.5 does not rotate while being pushed against the clutch hub No.3.
65. INSTALL SYNCHROMESH SHIFTING KEY SPRING NO.3
a) Install the synchromesh shifting key spring No.3 to the transmission clutch hub No.3.
NOTICE: Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.
b) Install the synchronizer ring set and synchromesh shifting key spring No.3 to the transmission clutch hub No.3.
NOTICE:
^ Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
^ Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install.
66. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
a) Using SST and a hammer, install the front transaxle case cover new oil seal.
SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
Oil seal driven in depth: 0 ± 0.5 mm (0 ± 0.020 inch)
b) Coat the front transaxle case cover oil seal lip with MP grease.
67. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a) Using SST and a hammer, install the FR differential case front tapered roller bearing (outer race) to the front transaxle case.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07100)
b) Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09950-70010 (09951-07100, 09951-07150), 09608-10010
68. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a) Install the front differential case shim rear.
b) Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race).
SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)
c) Using SST, install the FR differential case rear tapered roller bearing (inner race).
SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100)
69. INSTALL TRANSMISSION CASE OIL SEAL
a) Using SST and a hammer, install the transmission case new oil seal to the manual transmission case.
SST 09608-32010, 09950-70010 (09951-07150)
Oil seal driven in depth: 3.5 ± 0.5 mm (0.138 ± 0.020 inch)
b) Coat the transmission case oil seal lip with MP grease.