Part 2
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OVERHAUL
33. REMOVE REVERSE SHIFT ARM BRACKET ASSY
a. Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.
34. REMOVE GEAR SHIFT FORK SHAFT NO.2
a. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No.1.
b. Remove the gear shift fork shaft No.2 and gear shift head No.1 from the transaxle case.
35. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY NO.1
a. Using 2 screwdrivers and a hammer, tap out the snap rings.
HINT: Using a waste to prevent the snap ring from being scattered.
b. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No.1 from the gear shift fork No.1.
c. Remove the gear shift fork No.1.
36. REMOVE GEAR SHIFT FORK SHAFT NO.3
a. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No.3.
HINT: Using a waste to prevent the snap ring from being scattered.
b. Remove the shift fork shaft No.3 with reverse shift fork and gear shift fork No.2 from the transaxle case.
c. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
d. Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT: Using a waste to prevent the snap ring from being scattered.
e. Remove the reverse shift fork from the gear shift fork shaft No.3.
37. REMOVE INPUT SHAFT ASSY
a. Remove the input and output shaft assy from the transaxle case.
38. REMOVE DIFFERENTIAL CASE ASSY
a. Remove the differential case assy from the transaxle case.
39. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the bolt and manual transaxle case receiver from the transaxle case.
40. REMOVE REVERSE RESTRICT PIN ASSY
a. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
b. Using a pin punch (�5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assy from the manual transmission case.
41. REMOVE OIL RECEIVER PIPE NO.1 (MTM)
a. Remove the bolt and oil receiver pipe No.1 (MTM) from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No.1 (MTM).
42. REMOVE OIL RECEIVER PIPE NOW (MTM)
a. Remove the bolt and oil receiver pipe No.2 (MTM) from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No.2 (MTM).
43. REMOVE BEARING LOCK PLATE
a. Remove the bolt and bearing lock plate from the transaxle case.
44. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the transaxle case.
45. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST, remove the input shaft front bearing from the transaxle case.
SST 09612-65014 (09612-01050, 09612 01060)
46. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
47. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing from the transaxle case.
SST 0930-00010
48. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output shaft (MTM) cover from the transaxle case.
49. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST, remove FR differential case front tapered roller bearing (inner race) from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)
NOTICE: Be careful not to damage bearing.
50. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
51. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.
SST 09612-65014 (09612-01040, 09612-01050)
b. Using SST and a hammer, remove the FR 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: Be careful not to damage bearing.
52. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)
53. INSPECT SYNCHRONIZER RING NO.3
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone, check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE: Ensure the file lapping compound is completely washed off after rubbing.
c. Check again the breaking effect of the synchronizer ring.
d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 inch)
If the clearance is less than minimum, replace the synchronizer ring and gear cone by applying a small amount of the fine lapping compound on gear cone.
NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.
54. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No.3.
b. Check that spline gear's of the transmission hub sleeve No.3 is not worn down.
c. Using a vernier calipers, inspect the transmission hub sleeve No.3 and gear shift fork No.3, as shown in the illustration.
Standard clearance: 0.3 - 0.5 mm (0.012 - 0.020 inch)
If the clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3.
55. INSPECT 5TH GEAR
a. Using a caliper gauge, inspect 5th gear as shown in the illustration.
5th gear inner diameter
If the inner diameter exceeds the maximum, replace the 5th gear.