MANUAL TRANSAXLE UNIT (for Sedan) > DISASSEMBLY

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1. REMOVE MANUAL TRANSMISSION FILLER PLUG


C080549
  1. Remove the manual transmission filler plug and gasket from the manual transmission case.



2. REMOVE DRAIN PLUG SUB-ASSEMBLY


C080550
  1. Remove the drain plug sub-assembly and gasket from the manual transmission case.



3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
  1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.

  1. Remove the O-ring from the speedometer driven hole cover sub-assembly.



4. REMOVE SPEEDOMETER SENSOR (w/o ABS)
  1. Remove the bolt and speedometer sensor from the transaxle case.



5. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


C120749E01
  1. Separate the back-up light switch wire harness from the 2 clamps.

  1. 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


C120750
  1. Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.

  1. Remove the control shift lever bush.



7. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER


C120748
  1. Remove the nut and spring washer.



    C120747
  1. Using a brass bar and a hammer, remove the lock pin.

  1. Remove the floor shift control shift lever.



8. REMOVE SHIFT LEVER DAMPER


C120746
  1. Remove the nut and spring washer.



    C120745
  1. Using a brass bar and a hammer, remove the lock pin.

  1. Remove the shift lever damper.



9. FIX MANUAL TRANSAXLE ASSEMBLY


C080552E01
  1. Place the manual transaxle assembly on wooden blocks.



10. REMOVE LOCK BALL ASSEMBLY NO.1


C120744
  1. Remove lock ball assembly No. 1 from the manual transmission case.



11. REMOVE SHIFT GATE PIN


C120743
  1. Remove the shift gate pin and washer from the transmission case.



12. REMOVE CONTROL SHAFT COVER


C120742
  1. Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.



13. REMOVE CONTROL SHAFT COVER OIL SEAL


C120741
  1. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.



14. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY


C120740
  1. Remove the shift and select lever shaft assembly from the transmission case.



15. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY


C080554
  1. Remove the 9 bolts.



    C095189E01
  1. 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


C080341
  1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.



    Q006512
  1. Engage the 2 gears simultaneously to lock the transmission.

  1. Remove the manual transmission output shaft rear set nut.

  1. Disengage the 2 gears.



17. REMOVE GEAR SHIFT FORK NO.3


C080342
  1. Remove the gear shift fork lock bolt from gear shift fork No. 3.



    C080343
  1. Remove transmission hub sleeve No. 3 with gear shift fork No. 3 from transmission clutch hub No. 3.



18. INSPECT 5TH GEAR THRUST CLEARANCE


C080344
  1. 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.)
    If the clearance exceeds the maximum, replace transmission clutch hub No. 3, the 5th gear or input shaft rear radial ball bearing.


19. INSPECT 5TH GEAR RADIAL CLEARANCE


C080345
  1. 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.)
    If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.


20. REMOVE TRANSMISSION CLUTCH HUB NO. 3


    C080346
  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.


    C157373
  1. Using a screwdriver, remove the synchromesh shifting key spring from the transmission clutch hub No. 3.



    D032344E01
  1. 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)


    D032357
  1. 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


C080348
  1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.



22. REMOVE 5TH DRIVEN GEAR


C080349E01
  1. 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


C080350E01
  1. Remove the 5 bolts and bearing retainer rear from the manual transmission case.



24. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING


C080351
  1. 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


C080352
  1. 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


C067639
  1. 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


C080353
  1. 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


C067634
  1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.



    C067635
  1. 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.



    C080354
  1. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.



    C080355
  1. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.



29. REMOVE LOCK BALL ASSEMBLY NO.2


C080356
  1. Using a hexagon wrench, remove lock ball assembly No. 2 from the manual transmission case.



30. REMOVE MANUAL TRANSMISSION CASE


C080357
  1. Remove the 3 bolts from the front transaxle case.



    C080358
  1. Remove the 13 bolts from the manual transmission case.



    C067642
  1. 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


C080359
  1. 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


C080360
  1. Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.



33. REMOVE GEAR SHIFT FORK SHAFT NO.2


C080361
  1. Remove the 2 bolts from gear shift fork No. 2 and gear shift head No. 1.



    C080362E01
  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


C080363
  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.


    C080364E01
  1. Remove the shift fork set bolt and gear shift fork shaft No. 1 from gear shift fork No. 1.



    C080365E01
  1. Remove gear shift fork No. 1.



35. REMOVE GEAR SHIFT FORK SHAFT NO.3


C080366
  1. 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.


    C080367E01
  1. Remove shift fork shaft No. 3 together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.



    C080368
  1. Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.



    C080369
  1. 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.
  1. Remove the reverse shift fork from gear shift fork shaft No. 3.



36. REMOVE INPUT SHAFT ASSEMBLY


C080586
  1. Remove the input shaft assembly and output shaft assembly from the front transaxle case.



37. REMOVE DIFFERENTIAL CASE ASSEMBLY


C067656
  1. Remove the differential case assembly from the front transaxle case.



38. REMOVE MANUAL TRANSAXLE CASE RECEIVER


C067657
  1. Remove the bolt and manual transaxle case receiver from the front transaxle case.



39. REMOVE REVERSE RESTRICT PIN ASSEMBLY


C080372
  1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.



    C080373
  1. 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


C067644
  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


C080374
  1. 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


C067658
  1. Remove the bolt and bearing lock plate from the front transaxle case.



43. REMOVE TRANSMISSION MAGNET


C067659
  1. Remove the transmission magnet from the front transaxle case.



44. REMOVE INPUT SHAFT FRONT BEARING


C081783E01
  1. 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


C095411
  1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.



46. REMOVE OUTPUT SHAFT FRONT BEARING


C082141E01
  1. 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


C067719
  1. Remove the output shaft cover from the front transaxle case.



48. REMOVE FR0NT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


C081785E01
  1. 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)


    G026414E01
  1. 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


C081787E01
  1. 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


C081788E01
  1. 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)


    C082144E01
  1. 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


C081789E01
  1. 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


C121110
  1. Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.



53. REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING


C121111E01
  1. Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.

    SST
    09950-60010   (09951-00220)
    09950-70010   (09951-07200)