Manual Transaxle Unit: Removal

1. Remove the clutch release fork with the clutch release bearing from the transaxle case.

1. Remove the release bearing and clutch release bearing hub clip from the clutch release fork.

Fig 1: Identifying Clutch Release Bearing

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1. Remove the clutch release fork support from the transaxle case.

Fig 2: Identifying Clutch Release Fork Support

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1. Remove the clutch release fork boot from the manual transaxle case.

1. Remove the bolt and hole cover.
2. Remove the O-ring from the hole cover.

1. Remove the 2 bolts and selecting bellcrank assembly from the transmission case.
Fig 3: Identifying Selecting Bellcrank Assembly Bolt
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2. Remove the shift and select lever bush from the selecting bellcrank.

1. Remove the nut and spring washer.
   Fig 4: Identifying Nut And Spring Washer

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2. Using a brass bar and hammer, remove the shift outer lever lever lock pin.
3. Remove the control shift lever.

Fig 5: Identifying Shift Outer Lever Lever Lock Pin

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1. Remove the 4 bolts, control shift cover and gasket from the transmission case.

Fig 6: Identifying Bolts And Control Shift Cover

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1. Place the transaxle on wooden blocks.

Fig 7: Identifying Transaxle On Wooden Blocks

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1. Remove the lock ball from the transmission case.

Fig 8: Identifying Lock Ball

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1. Remove the breather plug and gasket.

Fig 9: Identifying Breather Plug And Gasket

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1. Remove the shift and select lever shaft from the transmission case.

Fig 10: Identifying Shift And Select Lever Shaft

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1. Remove the back-up light switch and gasket from the transmission case.

Fig 11: Identifying Back-Up Light Switch And Gasket

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1. Remove the filler plug and gasket from the transmission case.

Fig 12: Identifying Filler Plug

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1. Remove the drain plug and gasket from the transmission case.

Fig 13: Identifying Drain Plug

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1. Remove the 10 bolts and transmission case cover from the transmission case.

Fig 14: Identifying Transmission Case Cover Bolts

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1. Engage the 2 gears simultaneously to lock the transmission.
   Fig 15: Identifying Gears

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2. Using SST and a hammer, unstake the rear set nut.

   SST 09930-00010 

   Fig 16: Identifying Rear Set Nut

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3. Using SST, remove the shaft rear set nut from the output shaft.

   SST 09229-55010 

4. Disengage the 2 gears.

Fig 17: Removing Shaft Rear Set Nut From Output Shaft

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1. Using a dial indicator, measure the thrust clearance.

Standard clearance: 

0.10 to 0.65 mm (0.0039 to 0.0256 in.) 

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

Fig 18: Measuring Thrust Clearance

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1. Using a dial indicator, measure the radial clearance.

Standard clearance: 

0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

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

Fig 19: Identifying Radial Clearance

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

   HINT:

   Cover with a shop rag to keep the snap ring from flying off.

   Fig 20: Identifying No. 3 Transmission Clutch Hub Shaft Snap Ring

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2. Remove the shift fork set bolt from the No. 3 gear shift fork.
   Fig 21: Identifying Shift Fork Set Bolt

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3. 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), 09950-50013 (09957-04010), 09950-60010 (09951-00280) 

Fig 22: Removing No. 3 Transmission Clutch Hub, No. 3 Transmission Hub Sleeve And No. 3 Gear Shift Fork

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1. Remove the 5th gear from the input shaft.

Fig 23: Identifying 5th Gear

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1. Remove the needle roller bearing from the input shaft.

Fig 24: Identifying Needle Roller Bearing

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1. Using SST, remove the 5th driven gear from the output shaft.

SST 09950-30012(09951-03010,09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013 

Fig 25: Identifying 5th Driven Gear From Output Shaft

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

Fig 26: Identifying Rear Bearing Retainer And Torx Screws

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1. Remove the rear bearing shim from the output shaft.

Fig 27: Identifying Rear Bearing Shim From Output Shaft

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

Fig 28: Identifying Shaft Snap Ring From Input Shaft

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

   HINT:

   Cover with a shop rag to keep the snap ring from flying off.

   Fig 29: Identifying Shaft Snap Ring From No. 1 Gear Shift Fork Shaft

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

   HINT:

   Cover with a shop rag to keep the snap ring from flying off.

   Fig 30: Identifying Shaft Snap Ring From No. 2 Gear Shift Fork Shaft

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1. Remove the reverse idler gear shaft bolt and gasket.

1. Remove the bolt and clutch tube bracket.

Fig 31: Identifying Bolt And Clutch Tube Bracket

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1. Remove the 3 bolts from the transaxle case side.
   Fig 32: Identifying Transaxle Case Side Bolts

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2. Remove the 14 bolts from the transmission case side.
Fig 33: Identifying Transmission Case Side Bolts
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3. Tapping with a plastic-faced hammer, remove the transmission case.

1. Remove the bolt and No. 2 oil receiver pipe from the transmission case.

Fig 34: Identifying Bolt And No. 2 Oil Receiver Pipe

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1. Remove the bolt and oil receiver pipe from the transmission case.

Fig 35: Identifying Bolt And Oil Receiver Pipe

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1. Using a 6 mm hexagon wrench, remove the reverse restrict pin plug from the transmission case.
   Fig 36: Identifying Reverse Restrict Pin Plug

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2. Using a 5 mm pin punch, remove the slotted pin.
3. Remove the reverse restrict pin.

Fig 37: Identifying Slotted Pin

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1. Remove the transmission magnet from the transaxle case.

Fig 38: Identifying Transmission Magnet From Transaxle Case

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1. Remove the reverse idler gear with the reverse idler gear shaft from the transaxle case.
   Fig 39: Identifying Reverse Idler Gear

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2. Remove the reverse idler gear and reverse idler thrust washer from the gear shaft.
   Fig 40: Identifying Reverse Idler Gear And Reverse Idler Thrust Washer

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1. Remove the 2 bolts and reverse shift arm bracket from the transaxle case.

Fig 41: Identifying Reverse Shift Arm Bracket Bolts

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1. Remove the shift fork set bolt from the No. 1 gear shift fork.
   Fig 42: Identifying Shift Fork Set Bolt

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2. Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shift is pulled up.
   Fig 43: Identifying Pulling Out No 1 Gear Shift Fork Shaft

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

HINT:

Cover with a shop rag to keep the snap ring from flying off.

Fig 44: Identifying Shift Fork Shaft Snap Ring

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1. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.

Fig 45: Identifying Reverse Shift Fork Roller From Reverse Shift Fork

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1. Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.
   Fig 46: Identifying Shift Fork Set Bolt And Shift Head Set Bolt

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2. Remove the No. 2 gear shift fork shaft head and No. 1 gear shift head from the transaxle case.

Fig 47: Identifying No. 2 Gear Shift Fork Shaft Head

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1. Remove the No. 3 gear shift fork shaft from the transaxle case.
   Fig 49: Identifying No. 3 Gear Shift Fork Shaft

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2. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.

   HINT:

   Cover with a shop rag to keep the snap ring from flying off.

   Fig 50: Identifying Shift Fork Shaft Snap Rings

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3. Remove the reverse shift fork from the No. 3 gear shift fork shaft.

1. Remove the No. 2 gear shift fork from the input shaft.

Fig 51: Identifying No. 2 Gear Shift Fork

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1. Tilt the output shaft, then remove the input shaft from the transaxle case.

Fig 52: Identifying Input Shaft

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1. Slightly lift up on the differential case with the output shaft at an angle.
2. Remove the output shaft from the transaxle case.

Fig 53: Identifying Output Shaft From Transaxle Case

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1. Remove the differential case from the transaxle case.

Fig 54: Identifying Differential Case

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1. Remove the 3 bolts and transaxle case receiver from the transaxle case.

Fig 55: Identifying Transaxle Case Receiver And Bolts

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1. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.

SST 09612-65014(09612-01040, 09612-01050) 

Fig 56: Identifying Input Shaft Front Bearing

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1. Using SST, remove the oil seal from the transaxle case.

SST 09612-65014 (09612-01040, 09612-01050) 

Fig 57: Identifying Oil Seal From Transaxle Case

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

Fig 58: Removing Front Bearing

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1. Remove the output shaft cover from the transaxle case.

Fig 59: Identifying Output Shaft Cover From Transaxle Case

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

SST 09950-60010 (09951-00680), 09950-70010 (09951-07100) 

Fig 60: Tapping Out Rear Bearing From Transmission Case

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1. Using SST, tap out the oil seal from the transmission case.

SST 09308-00010 

Fig 61: Identifying Oil Seal From Transmission Case

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1. Using a screwdriver, pry out the cover oil seal.

HINT:

Tape the screwdriver tip before use to avoid damage.

Fig 62: Prying Out Cover Oil Seal

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1. Using a brass bar and hammer, tap out the front tapered roller bearing (outer race) from the transaxle case.
   Fig 63: Tapping Out Front Tapered Roller Bearing

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2. Using SST, remove the case front tapered roller bearing from the front differential case.

SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560) 

Fig 64: Identifying Case Front Tapered Roller Bearing

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1. 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), 09950-70010 (09951-07100) 

   Fig 65: Identifying Tapping Out Rear Tapered Roller Bearing (Outer Race) And Rear Shim

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2. Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.

SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490) 

Fig 66: Identifying Rear Tapered Roller Bearing (Inner Race)

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

   Standard inside diameter 

   INSIDE DIAMETER SPECIFICATION
   
   

   Standard Inside Diameter	Maximum Inside Diameter
   20.056 to 20.074 mm (0.7896 to 0.7903 in.)	20.074 mm (0.7903 in.)

   Fig 67: Measuring Inside Diameter Of Reverse Idler Gear

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

2. Using a micrometer, measure the outside diameter of the reverse idler gear shaft.

   Standard outside diameter 

   OUTSIDE DIAMETER SPECIFICATION
   
   

   Standard Outside Diameter	Minimum Outside Diameter
   19.984 to 20.000 mm (0.7868 to 0.7874 in.)	19.984 mm (0.7868 in.)

   Fig 68: Measuring Outside Diameter Of Reverse Idler Gear Shaft

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

1. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.

Fig 69: Identifying No. 3 Transmission Hub Sleeve

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1. 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.

Fig 70: Removing No. 3 Synchromesh Shifting Key Spring

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1. Using a screwdriver, remove the synchronizer pull ring snap ring.
2. Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner and No. 5 synchronizer ring middle.

Fig 71: Identifying Synchronizer Pulling Ring Snap Ring

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1. Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve.
2. Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear.

Fig 72: Identifying Sliding Condition Between No. 3 Transmission Clutch Hub

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1. 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.) 

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

Fig 73: Inspecting No. 3 Transmission Hub Sleeve

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

   Standard inside diameter 

   INSIDE DIAMETER SPECIFICATION
   
   

   Standard Inside Diameter	Maximum Inside Diameter
   34.981 to 34.997 mm (1.3772 to 1.3778 in.)	34.997 mm (1.3778 in.)

   Fig 74: Measuring Inside Diameter Of 5th Gear

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