Part 1

MANUAL TRANSAXLE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

DISASSEMBLY

1. REMOVE CLUTCH RELEASE FORK SUBASSEMBLY
(a) Remove the clutch release fork subassembly together with the clutch release bearing assembly from the manual transaxle case.

2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork subassembly.

3. REMOVE RELEASE FORK SUPPORT
(a) Remove the release fork support from the manual transaxle case.

4. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the manual transaxle case.

5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUBASSEMBLY
(a) Remove the bolt and speedometer driven hole cover subassembly.
(b) Remove the O-ring.

6. REMOVE SELECTING BELLCRANK ASSEMBLY
(a) Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.

7. REMOVE CONTROL SHIFT LEVER
(a) Remove the nut and spring washer.

(b) Using a brass bar and hammer, remove the shift outer lever lock pin.
(c) Remove the control shift lever.

8. REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts and control shaft cover from the manual transmission case.

9. SECURE MANUAL TRANSAXLE ASSEMBLY
(a) Place the manual transaxle assembly on wooden blocks.

10. REMOVE NO. 1 LOCK BALL ASSEMBLY
(a) Remove the No. 1 lock ball assembly from the manual transmission case.

11. REMOVE SHIFT GATE PIN
(a) Remove the shift gate pin from the manual transmission case.

12. REMOVE MANUAL TRANSMISSION BREATHER PLUG
(a) Remove the manual transmission breather plug.

13. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Remove the shift and select lever shaft assembly from the manual transmission case.

14. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
(a) Remove the back-up light switch assembly and gasket from the manual transmission case.

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

16. REMOVE DRAIN PLUG SUBASSEMBLY
(a) Remove the drain plug subassembly and gasket from the manual transmission case.

17. REMOVE MANUAL TRANSMISSION CASE COVER SUBASSEMBLY
(a) Remove the 10 bolts and manual transmission case cover from the manual transmission case.

18. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
(a) Engage the 1st and 2nd gears simultaneously.

(b) Using SST and a hammer, unstake the manual transmission output shaft rear set nut.
SST 09930-00010

(c) Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
SST 09229-55010
(d) Disengage the gears.

19. REMOVE NO. 3 TRANSMISSION CLUTCH HUB
(a) Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.

HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.

(b) Remove the shift fork set bolt from the No. 3 gear shift fork.

(c) Using SST, remove the No. 3 transmission clutch hub 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)

20. REMOVE 5TH GEAR
(a) Remove the 5th gear from the input shaft.

21. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing from the input shaft.

22. 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, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013

23. REMOVE REAR BEARING RETAINER
(a) Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.

24. REMOVE OUTPUT SHAFT REAR BEARING SHIM
(a) Remove the output shaft rear bearing shim from the output shaft.

25. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
(a) Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.

26. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the No. 1 gear shift fork shaft.

HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.

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

HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.

27. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and gasket.

28. REMOVE NO. 1 CLUTCH TUBE BRACKET
(a) Remove the bolt and clutch tube bracket.

29. REMOVE MANUAL TRANSMISSION CASE
(a) Remove the 3 bolts from the manual transaxle case.

(b) Remove the 14 bolts from the manual transmission case.
(c) Tapping with a plastic hammer, remove the manual transmission case.

30. REMOVE REVERSE RESTRICT PIN ASSEMBLY
(a) Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.

(b) Using a pin punch (5 mm) and hammer, remove the slotted pin.

31. REMOVE NO. 2 OIL RECEIVER PIPE
(a) Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.

NOTICE: Do not damage the pipe.

32. REMOVE NO. 1 OIL RECEIVER PIPE
(a) Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.

NOTICE: Do not damage the pipe.