Part 2

MANUAL TRANSAXLE UNIT

DISASSEMBLY (Continued)





33. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the manual transaxle case.





34. REMOVE REVERSE IDLER GEAR SUBASSEMBLY
(a) Remove the reverse idler gear subassembly from the manual transaxle case.





(b) Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.





35. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case.





36. REMOVE NO. 1 GEAR SHIFT FORK SHAFT
(a) Remove the shift fork set bolt from the No. 1 gear shift fork.





(b) Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shaft is pulled up.





(c) Using 2 screwdrivers and a hammer, remove the shift fork 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.





37. REMOVE REVERSE SHIFT FORK ROLLER
(a) Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.





38. REMOVE NO. 2 GEAR SHIFT FORK SHAFT
(a) Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.





(b) Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the manual transaxle case.





39. REMOVE NO. 1 GEAR SHIFT FORK
(a) Remove the No. 1 gear shift fork.





40. REMOVE NO. 3 GEAR SHIFT FORK SHAFT
(a) Remove the No. 3 gear shift fork shaft from the manual transaxle case.





(b) Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.
(c) Remove the reverse shift fork from the No. 3 gear shift fork shaft.





41. REMOVE NO. 2 GEAR SHIFT FORK
(a) Remove the No. 2 gear shift fork from the input shaft assembly.





42. REMOVE INPUT SHAFT ASSEMBLY
(a) Tilt the output shaft, then remove the input shaft from the manual transaxle case.





43. REMOVE OUTPUT SHAFT ASSEMBLY
(a) Lift the differential case assembly with the output shaft assembly leaned.
(b) Remove the output shaft assembly from the manual transaxle case.





44. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the differential case assembly from the manual transaxle case.





45. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.





46. 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)





47. 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)





48. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.
SST 09387-00041 (09387-02020, 09387-02010)





49. REMOVE OUTPUT SHAFT COVER
(a) Remove the output shaft cover from the manual transaxle case.





50. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using SST and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race).
SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)





51. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST, remove the transmission case oil seal from the manual transmission case.
SST 09308-00010





52. 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.





53. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using a brass bar and a hammer, remove the front 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)





54. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07100)





(b) Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
SST 09950-60020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490)





55. REMOVE NO. 3 TRANSMISSION HUB SLEEVE
(a) Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.





56. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING
(a) Remove the 2 No. 3 synchromesh shifting key springs from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.





57. REMOVE SYNCHRONIZER PULL RING
(a) Using a screwdriver, remove the synchronizer pull ring snap ring.
(b) Remove the synchronizer pull ring, No. 5 synchronizer outer ring, No. 5 synchronizer inner ring, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner.