Basic Subassembly Separation

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
Remove the back-up light switch.




3. REMOVE VEHICLE SPEED SENSOR
a. Remove the set bolt and lock plate.
b. Remove the vehicle speed sensor.




4. REMOVE SELECTING BELLCRANK ASSEMBLY




5. REMOVE SHIFT LEVER
a. Remove the shift lever set nut.




b. Using a pin punch and hammer, tap out the lock pin.




6. REMOVE LOCK BOLT




7. REMOVE CONTROL SHAFT COVER
Remove the 4 bolts holding the control shaft cover.




8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY




9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and case cover.




10. REMOVE BREATHER PLUG WITH GASKET




11. REMOVE LOCK NUT
a. Unstake the lock nut.
b. Engage the gear double meshing.




c. Remove the lock nut.
d. Disengage the gear double meshing.




12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
b. Remove the No.3 hub sleeve and No.3 shift fork.




13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-30010




14. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE
a. Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)




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

Standard clearance: 0.009 - 0.060 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)




15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear.
SST 09950-30010
16. REMOVE NEEDLE ROLLER BEARING AND SPACER




17. REMOVE REAR BEARING RETAINER
a. Using a torx socket wrench, remove the 7 torx screws and bearing retainer.
(Torx wrench T45 09042-00050)
b. Remove the adjust shim.




18. REMOVE SNAP RING
a. Using a snap ring expander, remove the snap ring.




b. Using 2 screwdrivers and a hammer, remove the 3 snap rings.




19. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL
a. Using a hexagon wrench (6 mm), remove the plug.
b. Using a magnetic finger, remove the seat, spring and locking ball.




20. REMOVE REVERSE IDLER GEAR SHAFT RETAINING BOLT




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




b. Remove the 14 bolts from the transmission side and tap the case with a plastic hammer.




22. REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE
a. Remove the shim.




b. Using SST and a hammer, remove the output shaft rear taper roller bearing outer race.
SST 09316-60010 (09316-00010)




23. REMOVE NO.2 OIL PIPE
a. Remove the gasket.
b. Remove the 2 bolts and oil pipe.




24. REMOVE REVERSE SHIFT ARM BRACKET
Remove the bolt and pull off the bracket.




25. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear.




26. REMOVE STRAIGHT SCREW PLUGS. LOCKING BALLS AND SPRINGS
a. Using a hexagon wrench (6 mm), remove the 2 plugs.
b. Using a magnetic finger, remove the 2 spring seats, springs and balls.




27. REMOVE 3 SET BOLTS




28. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.




29. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.




30. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK
a. Pull out the No.2 shift fork shaft.
b. Remove the shift head and No.1 shift fork.




31. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK
a. Pull out the No.3 shift fork shaft with the reverse shift fork.
b. Remove the No.2 shift fork.




32. REMOVE SNAP RINGS
a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the snap rings from the No.1, No.2 and No.3 shift fork shafts.




33. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY
a. Leaning the output shaft to the differential side, remove the input shaft assembly.




b. Lift up the differential case assembly, remove the output shaft.




34. REMOVE DIFFERENTIAL ASSEMBLY
a. Remove the oil pump drive gear.




b. Remove the differential case assembly.




35. REMOVE MAGNET FROM TRANSAXLE CASE




36. REMOVE OIL PUMP ASSEMBLY
a. Remove the 2 bolts and oil pipe.




b. Remove the 2 bolts and oil pump.




37. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB
a. Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub.




b. Using a screwdriver, remove the snap ring.

HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

c. Remove the synchronizer rings.