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Disassembly






EB62 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: DISASSEMBLY

1. REMOVE MANUAL TRANSMISSION FILLER PLUG

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





2. REMOVE MANUAL TRANSMISSION DRAIN PLUG

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





3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using a (27 mm) deep socket wrench, remove the back-up light switch and gasket from the manual transmission case.





4. REMOVE TRANSMISSION CASE PLUG

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





5. REMOVE CONTROL CABLE BRACKET

(a) Remove the 2 bolts and control cable bracket from the manual transmission case.





6. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

(a) Remove the bleeder plug cap from the release cylinder bleeder plug.

7. REMOVE RELEASE CYLINDER BLEEDER PLUG

(a) Remove the bleeder plug from the clutch release bleeder sub-assembly.

8. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY Removal

9. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY Removal

10. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE Removal

11. REMOVE FLOOR SHIFT CONTROL BELLCRANK DUST COVER

(a) Remove the floor shift control bellcrank dust cover from the floor shift selecting bell crank assembly.





12. REMOVE FLOOR SHIFT SELECTING BELLCRANK ASSEMBLY

(a) Remove the 2 bolts, nut, wave washer, and floor shift selecting bellcrank assembly from the manual transmission case.





13. REMOVE FLOOR SHIFT CONTROL SHAFT ASSEMBLY

(a) Remove the nut, wave washer, and floor shift control shaft assembly from the floor shift selecting bellcrank assembly.





14. SECURE MANUAL TRANSAXLE ASSEMBLY

(a) Place the manual transaxle on wooden blocks.





15. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.





16. REMOVE LOCK BALL PIN

(a) Using a (10 mm) hexagon socket wrench, remove the plug from the manual transmission case.





(b) Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.





(c) Using a (10 mm) hexagon socket wrench, remove the plug from the manual transmission case.

(d) Using a magnet hand, remove the compression spring and lock ball pin from the manual transmission case.

17. REMOVE SHIFT DETENT BALL

(a) Using a (6 mm) hexagon socket wrench, remove the shift detent ball plug from the manual transmission case.





(b) Using a magnet hand, remove the compression spring and shift detent ball from the manual transmission case.

(c) Using a (6 mm), hexagon socket wrench, remove the 2 shift detent ball plugs from the manual transmission case.





(d) Using a magnet hand, remove the 2 compression springs and 2 shift detent balls from the manual transmission case.

18. REMOVE OUTER SHIFT LEVER E RING

(a) Remove the E ring from the outer No. 1 shift lever.





19. REMOVE MANUAL TRANSMISSION CASE SUB-ASSEMBLY

(a) Remove the 17 bolts.





(b) Using a screwdriver with its tip wrapped with protective tape, separate the manual transmission case from the front transaxle case.





Text in Illustration:





NOTICE:
Do not damage the manual transmission case.

(c) Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.





(d) Push the outer No. 1 shift lever and remove the manual transmission case.





20. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.





21. REMOVE REVERSE SHIFT FORK

(a) Turn the reverse shift fork shaft clockwise and remove it from the front transaxle case.





(b) Using a (5 mm) pin punch and hammer, tap out the reverse shift fork slotted spring pin.





(c) Remove the reverse shift fork from the No. 1 gear shift fork shaft.

22. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Using a (6 mm) hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket from the front transaxle case.





23. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the inner select lever set bolt.





(b) Turn the shift and select lever shaft clockwise and remove it from the front transaxle case.





24. REMOVE OUTER SELECT LEVER

(a) Remove the outer select lever and inner select lever from the front transaxle case.





25. REMOVE OUTER SELECT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the front transaxle case.





Text in Illustration:





NOTICE:
Do not damage the installation surfaces.

26. REMOVE INPUT SHAFT ASSEMBLY

(a) Remove the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.





(b) Remove the output shaft assembly together with the No. 1 gear shift fork shaft assembly from the input shaft assembly.

(c) Remove the No. 1 gear shift fork shaft assembly from the output shaft assembly.

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

27. REMOVE DIFFERENTIAL CASE ASSEMBLY

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





28. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential oil baffle from the front transaxle case.





SST : 09308-00010

(b) Using SST, remove the differential case assembly front tapered roller bearing from the differential case assembly.





Text in Illustration:





SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00350

09951-00550

09952-06010

29. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.





SST : 09308-00010

(b) Using SST, remove the front differential case rear tapered roller bearing from the front differential case assembly.





Text in Illustration:





SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04021

09957-04010

09958-04011

SST : 09950-60010

09951-00350

09951-00550

09952-06010

30. REMOVE TRANSMISSION MAGNET

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





31. REMOVE BREATHER PLUG

(a) Remove the breather plug from the front transaxle case.





32. REMOVE FRONT OUTPUT SHAFT BEARING

(a) Using SST, tap the front output shaft bearing (outer race) from the front transaxle case.





SST : 09308-00010

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





33. REMOVE FRONT TRANSAXLE CASE OIL SEAL

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





SST : 09950-60010

09951-00360

SST : 09950-70010

09951-07150

34. REMOVE STRAIGHT PIN

(a) Remove the 5 straight pins from the front transaxle case.





35. REMOVE REAR INPUT SHAFT BEARING SHIM

(a) Remove the rear input shaft bearing shim from the manual transmission case.





36. REMOVE INPUT SHAFT COVER

(a) Remove the input shaft cover from the manual transmission case.





37. REMOVE NO. 1 OIL RECEIVER PIPE

(a) Remove the No. 1 oil receiver pipe from the manual transmission case.





38. REMOVE OUTER NO. 1 SHIFT LEVER

(a) Using a (5 mm) pin punch and hammer, tap out the inner shift lever slotted spring pin.





HINT
When removing the slotted spring pin, align the pin with the hole in the lock ball assembly.

(b) Remove the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever from the manual transmission case.

39. REMOVE OUTER SHIFT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the front transaxle case.





Text in Illustration:





NOTICE:
Do not damage the installation surfaces.

40. REMOVE REAR OUTPUT SHAFT BEARING

(a) Using SST, remove the rear output shaft bearing (outer race) and rear output shaft bearing shim from the manual transmission case.





SST : 09308-00010

41. REMOVE TRANSMISSION CASE OIL SEAL

(a) for LH Side:





(1) Using SST, remove the transmission case oil seal from the manual transmission case.

SST : 09308-00010

(b) for RH Side:





(1) Using SST, remove the transmission case oil seal from the front transaxle case.

SST : 09308-00010
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