MANUAL TRANSAXLE UNIT (for Sedan) > DISASSEMBLY |
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1. REMOVE MANUAL TRANSMISSION FILLER PLUG |
Remove the manual transmission filler plug and gasket from the manual transmission case.
2. REMOVE DRAIN PLUG SUB-ASSEMBLY |
Remove the drain plug sub-assembly and gasket from the manual transmission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY |
Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
Remove the O-ring from the speedometer driven hole cover sub-assembly.
4. REMOVE SPEEDOMETER SENSOR (w/o ABS) |
Remove the bolt and speedometer sensor from the transaxle case.
5. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY |
Separate the back-up light switch wire harness from the 2 clamps.
Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.
- SST
- 09817-16011
6. REMOVE SELECTING BELL CRANK ASSEMBLY |
Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.
Remove the control shift lever bush.
7. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER |
Remove the nut and spring washer.
Using a brass bar and a hammer, remove the lock pin.
Remove the floor shift control shift lever.
8. REMOVE SHIFT LEVER DAMPER |
Remove the nut and spring washer.
Using a brass bar and a hammer, remove the lock pin.
Remove the shift lever damper.
9. FIX MANUAL TRANSAXLE ASSEMBLY |
Place the manual transaxle assembly on wooden blocks.
10. REMOVE LOCK BALL ASSEMBLY NO.1 |
Remove lock ball assembly No. 1 from the manual transmission case.
11. REMOVE SHIFT GATE PIN |
Remove the shift gate pin and washer from the transmission case.
12. REMOVE CONTROL SHAFT COVER |
Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.
13. REMOVE CONTROL SHAFT COVER OIL SEAL |
Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
14. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY |
Remove the shift and select lever shaft assembly from the transmission case.
15. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY |
Remove the 9 bolts.
Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.
- NOTICE:
- Do not damage the manual transmission case.
16. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT |
Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
Engage the 2 gears simultaneously to lock the transmission.
Remove the manual transmission output shaft rear set nut.
Disengage the 2 gears.
17. REMOVE GEAR SHIFT FORK NO.3 |
Remove the gear shift fork lock bolt from gear shift fork No. 3.
Remove transmission hub sleeve No. 3 with gear shift fork No. 3 from transmission clutch hub No. 3.
18. INSPECT 5TH GEAR THRUST CLEARANCE |
Using a dial indicator, measure the 5th gear thrust clearance.
- Standard clearance:
- 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
- Maximum clearance:
- 0.55 mm (0.0217 in.)
19. INSPECT 5TH GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 5th gear radial clearance.
- Standard clearance:
- KOYO made:
- 0.015 to 0.058 mm (0.0006 to 0.0023 in.)
- NSK made:
- 0.015 to 0.056 mm (0.0006 to 0.0022 in.)
- Maximum clearance:
- KOYO made:
- 0.058 mm (0.0023 in.)
- NSK made:
- 0.056 mm (0.0022 in.)
20. REMOVE TRANSMISSION CLUTCH HUB NO. 3 |
Using 2 screwdrivers and a hammer, tap out the snap ring.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
Using a screwdriver, remove the synchromesh shifting key spring from the transmission clutch hub No. 3.
Using SST, remove the transmission clutch hub No. 3, 5th gear, and synchronizer ring No. 3 from the input shaft.
- SST
- 09950-50013
(09951-05010, 09952-05010, 09953-05020, 09954-05031, 09957-04010)
09950-60010 (09951-00200)
Remove the 3 synchromesh shifting keys and synchromesh shifting key spring from the transmission clutch hub No. 3.
21. REMOVE 5TH GEAR NEEDLE ROLLER BEARING |
Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
22. REMOVE 5TH DRIVEN GEAR |
Using SST, remove the 5th driven gear from the output shaft.
- SST
- 09950-30012
(09951-03010, 09953-03010, 09954-03010, 09955-03021)
09950-60010 (09951-00180)
23. REMOVE BEARING RETAINER REAR |
Remove the 5 bolts and bearing retainer rear from the manual transmission case.
24. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING |
Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
25. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING |
Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
26. REMOVE REVERSE IDLER GEAR SHAFT BOLT |
Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case.
27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING |
Using 2 screwdrivers and a hammer, tap out the snap ring from gear shift fork shaft No. 2.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
28. REMOVE SHIFT DETENT BALL |
Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
Using a magnetic finger, remove the 2 shift detent ball spring seats No. 1, 2 shift detent ball springs and 2 shift detent balls from the manual transmission case.
Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
29. REMOVE LOCK BALL ASSEMBLY NO.2 |
Using a hexagon wrench, remove lock ball assembly No. 2 from the manual transmission case.
30. REMOVE MANUAL TRANSMISSION CASE |
Remove the 3 bolts from the front transaxle case.
Remove the 13 bolts from the manual transmission case.
Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.
- NOTICE:
- Do not damage the manual transmission case and transaxle case.
31. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY |
Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the front transaxle case.
32. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY |
Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.
33. REMOVE GEAR SHIFT FORK SHAFT NO.2 |
Remove the 2 bolts from gear shift fork No. 2 and gear shift head No. 1.
Remove gear shift fork shaft No. 2 and gear shift head No. 1 from the front transaxle case.
34. REMOVE GEAR SHIFT FORK SHAFT NO.1 |
Using 2 screwdrivers and a hammer, tap out the snap ring.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
Remove the shift fork set bolt and gear shift fork shaft No. 1 from gear shift fork No. 1.
Remove gear shift fork No. 1.
35. REMOVE GEAR SHIFT FORK SHAFT NO.3 |
Using 2 screwdrivers and a hammer, tap out the snap ring from gear shift fork shaft No. 3.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
Remove shift fork shaft No. 3 together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.
Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
Using 2 screwdrivers and a hammer, tap the snap ring out of shift fork shaft No. 3.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
Remove the reverse shift fork from gear shift fork shaft No. 3.
36. REMOVE INPUT SHAFT ASSEMBLY |
Remove the input shaft assembly and output shaft assembly from the front transaxle case.
37. REMOVE DIFFERENTIAL CASE ASSEMBLY |
Remove the differential case assembly from the front transaxle case.
38. REMOVE MANUAL TRANSAXLE CASE RECEIVER |
Remove the bolt and manual transaxle case receiver from the front transaxle case.
39. REMOVE REVERSE RESTRICT PIN ASSEMBLY |
Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
Using a pin punch (φ5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.
40. REMOVE OIL RECEIVER PIPE NO. 1 |
Remove the bolt and oil receiver pipe No. 1 from the manual transmission case.
- NOTICE:
- Do not damage oil receiver pipe No. 1.
41. REMOVE OIL RECEIVER PIPE NO. 2 |
Remove the bolt and oil receiver pipe No. 2 from the manual transmission case.
- NOTICE:
- Do not damage oil receiver pipe No. 2.
42. REMOVE BEARING LOCK PLATE |
Remove the bolt and bearing lock plate from the front transaxle case.
43. REMOVE TRANSMISSION MAGNET |
Remove the transmission magnet from the front transaxle case.
44. REMOVE INPUT SHAFT FRONT BEARING |
Using SST, remove the input shaft front bearing from the front transaxle case.
- SST
- 09612-65014
(09612-01050, 09612-01060)
45. REMOVE FRONT TRANSAXLE CASE OIL SEAL |
Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
46. REMOVE OUTPUT SHAFT FRONT BEARING |
Using SST, remove the output shaft front bearing from the front transaxle case.
- SST
- 09308-00010
- NOTICE:
- Do not apply excessive force to the front transaxle case when installing it.
47. REMOVE OUTPUT SHAFT COVER |
Remove the output shaft cover from the front transaxle case.
48. REMOVE FR0NT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING |
Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
- SST
- 09612-65014
(09612-01040, 09612-01050)
Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
- SST
- 09950-00020
09950-00030
09950-40011 (09957-04010)
09950-60010 (09951-00360)
- NOTICE:
- Do not damage the bearing.
49. REMOVE TRANSAXLE CASE OIL SEAL |
Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.
- SST
- 09950-60010
(09951-00530)
09950-70010 (09951-07150)
50. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING |
Using SST, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
- SST
- 09612-65014
(09612-01040, 09612-01050)
Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
- SST
- 09950-40011
(09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60010 (09951-00360)
- NOTICE:
- Do not damage the bearing.
51. REMOVE TRANSMISSION CASE OIL SEAL |
Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
- SST
- 09950-60010
(09951-00530)
09950-70010 (09951-07150)
52. REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL |
Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.
53. REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING |
Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.
- SST
- 09950-60010
(09951-00220)
09950-70010 (09951-07200)