Part 1

C50 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT (for Hatchback): DISASSEMBLY

1. REMOVE MANUAL TRANSMISSION FILLER PLUG

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

2. REMOVE DRAIN PLUG SUB-ASSEMBLY

(a) Remove the drain plug sub-assembly and gasket from the manual transmission case.

3. REMOVE BACK UP LIGHT SWITCH ASSEMBLY

(a) Separate the back up light switch wire harness from the 2 clamps.

(b) Using SST, remove the back up light switch assembly and gasket from the manual transmission case.

SST : 09817-16011

4. REMOVE SELECTING BELL CRANK ASSEMBLY

(a) Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.

(b) Remove the control bell crank dust cover.

5. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER

(a) Remove the nut and spring washer.

(b) Using a brass bar and a hammer, remove the lock pin.

(c) Remove the shift lever damper and dust boot.

7. FIX MANUAL TRANSAXLE ASSEMBLY

(a) Place the manual transaxle assembly on wooden blocks.

Text in Illustration

8. REMOVE NO. 1 LOCK BALL ASSEMBLY

(a) Remove the No. 1 lock ball assembly from the manual transmission case.

9. REMOVE SHIFT GATE PIN

(a) Remove the shift gate pin and washer from the manual transmission case.

10. REMOVE CONTROL SHAFT COVER

(a) Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.

11. REMOVE CONTROL SHAFT COVER OIL SEAL

(a) Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.

12. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the shift and select lever shaft assembly from the manual transmission case.

13. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY

(a) Remove the 9 bolts.

(b) Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove the manual transmission case cover sub-assembly from the manual transmission case.

Text in Illustration

NOTICE:
Do not damage the manual transmission case.

14. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT

(a) Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.

(b) Engage the 2 gears simultaneously to lock the transmission.

(c) Remove the manual transmission output shaft rear set nut.

(d) Disengage the 2 gears.

15. REMOVE NO. 3 GEAR SHIFT FORK

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

(b) Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.

16. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 5th gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, the 5th gear or input shaft rear radial ball bearing.

17. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance:

JTEKT made
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

NSK made
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

Maximum clearance:

JTEKT made
0.058 mm (0.00228 in.)

NSK made
0.056 mm (0.00220 in.)

If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft assembly.

18. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

(a) Using 2 screwdrivers and a hammer, tap out the No. 3 clutch hub shaft snap ring.

HINT
Use a piece of cloth to keep the snap ring from flying off.

(b) Using a screwdriver, remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.

(c) Using SST, remove the No. 3 transmission clutch hub, 5th gear, and the No. 3 synchronizer ring from the input shaft assembly.

SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05031

09957-04010

SST : 09950-60010

09951-00200

(d) Remove the 3 synchromesh shifting keys and synchromesh shifting key spring from the No. 3 transmission clutch hub.

19. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

(a) Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft assembly.

20. REMOVE 5TH DRIVEN GEAR

(a) Using SST, remove the 5th driven gear from the output shaft assembly.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03021

SST : 09950-60010

09951-00180

21. REMOVE REAR BEARING RETAINER

(a) Remove the 5 bolts and rear bearing retainer from the manual transmission case.

22. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft assembly.

23. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft assembly.

24. REMOVE REVERSE IDLER GEAR SHAFT BOLT

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

25. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING

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

HINT
Use a piece of cloth to keep the snap ring from flying off.

26. REMOVE SHIFT DETENT BALL

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

(b) Using a magnetic finger, remove the 2 spring seats, the compression springs and 2 shift detent balls from the manual transmission case.

(d) Using a magnetic finger, remove the spring seat, compression spring and shift detent ball from the front transaxle case.

27. REMOVE NO. 2 LOCK BALL ASSEMBLY

(a) Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.

28. REMOVE MANUAL TRANSMISSION CASE

(a) Remove the 3 bolts from the front transaxle case.

(b) Remove the 13 bolts from the manual transmission case.

(c) Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the manual transmission case from the transaxle case.

NOTICE:
Do not damage the manual transmission case and transaxle case.

29. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

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