Part 1
OVERHAUL1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY
a. Remove the bolt and speedometer driven hole cover sub-assy.
b. Remove the O-ring from the speedometer driven hole cover sub-assy.
2. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork sub-assy with clutch release bearing assy from the transaxle case.
3. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing hub clip and clutch release bearing assy from the clutch release fork sub-assy.
4. REMOVE RELEASE FORK SUPPORT
a. Remove release fork support from the transaxle case.
5. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the transaxle case.
6. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
7. REMOVE SELECTING BELLCRANK ASSY
a. Remove the 2 bolts and selecting bellcrank assy from the manual transmission case.
8. FIX MANUAL TRANSAXLE ASSY
a. Using wooden blocks, fix the manual transaxle assy.
9. REMOVE MANUAL TRANSMISSION FILLER PLUG
a. Remove the manual transmission filler plug and gasket from the manual transmission case cover.
10. REMOVE DRAIN (MTM) PLUG SUB-ASSY
a. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
11. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY
a. Remove the 9 bolts.
b. Using a brass bar and a hammer, remove the manual transmission case cover sub-assy.
NOTICE: Do not damage the manual transmission case cover sub-assy.
12. INSPECT 6TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the 6th gear thrust clearance.
Standard clearance: 0.10 - 0.60 mm (0.0039 - 0.0236 inch)
13. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance: 0.10 - 0.62 mm (0.0039 - 0.0244 inch)
14. INSPECT 6TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 6th gear radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)
If the clearance is out of the specification, replace the 6th gear needle roller bearing.
15. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance: 0.015 - 0.056 mm (0.0006 - 0.0022 inch)
If the clearance is out of specification, replace the 5th gear needle roller bearing.
16. REMOVE COUNTER GEAR 6TH
a. Using 2 screwdrivers and a hammer, remove the output shaft RR snap ring from the output shaft.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
b. Using SST, remove output shaft RR bearing with 6th counter gear from the output shaft.
SST 09950-40011 (09951 -04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011), 09950-60010 (09951-00190)
17. REMOVE OUTPUT GEAR SPACER
a. Remove the output gear spacer from the output shaft.
18. REMOVE 6TH GEAR SUB-ASSY
a. Using 2 screwdrivers and a hammer, remove the input shaft snap ring from the input shaft.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
b. Using SST, remove the input shaft radial ball bearing RR with 6th gear sub-assy from the input shaft.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011)
19. REMOVE 6TH GEAR NEEDLE ROLLER BEARING
a. Remove 6th gear needle roller bearing from the input shaft.
20. REMOVE SYNCHRONIZER RING No. 3 (FOR 6TH GEAR MT)
a. Remove the synchronizer ring No. 3 from the input shaft.
21. REMOVE TRANSMISSION CLUTCH HUB No. 3
a. Remove the 6th gear spacer.
b. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
c. Remove the shift fork lock bolt from the shift fork No. 3.
d. Using SST, remove the transmission clutch hub No. 3 with gear shift fork No. 3 from the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09957-04010), 09950-50013 (09954-05040)
22. REMOVE SYNCHRONIZER RING No. 3 (FOR 5TH GEAR MT)
a. Remove the synchronizer ring No. 3 from the 5th gear.
23. REMOVE 5TH GEAR
a. Remove the 5th gear from the input shaft.
24. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
a. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
b. Remove the 5th gear needle roller bearing and 2 5th gear bearing spacers from the input shaft.
25. REMOVE 5TH DRIVEN GEAR
a. Using SST, remove the 5th driven gear from the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)
26. REMOVE SHIFT FORK SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the shift fork shaft No. 2.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
27. REMOVE BEARING RETAINER REAR (MTM)
a. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
28. REMOVE LOCK BALL ASSY No. 1
a. Remove the lock ball assy No. 1 from the manual transmission case.
29. REMOVE SHIFT & SELECT LEVER SHAFT ASSY
a. Remove the 4 bolts and shift & select lever shaft assy and gasket from the manual transmission case.
30. REMOVE BACK UP LAMP SWITCH ASSY
a. Using SST, remove the back up lamp switch assy and gasket from the manual transmission case.
SST 09817-16011
31. REMOVE SHIFT DETENT BALL
a. Using a socket hexagon wrench 6, remove the 2 shift detent ball plugs from the manual transmission case.
b. Using a magnetic finger, remove the 2 shift detent ball spring seats, 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.
32. 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.
33. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, remove the input shaft rear bearing hole snap ring.
34. REMOVE MANUAL TRANSMISSION CASE PLUG
a. Using a socket hexagon wrench 6, remove the manual transmission case plug from the manual transmission case.
35. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
36. REMOVE MANUAL TRANSMISSION CASE
a. Remove the 3 bolts from the transaxle case side.
b. Remove the 13 bolts from manual transmission case side.
c. Using a brass bar and a hammer, remove the manual transmission case from the transaxle case.
37. REMOVE OIL RECEIVER PIPE No. 1 (MTM)
a. Remove the bolt and oil receiver pipe No. 1 from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No. 1.
38. REMOVE OIL RECEIVER PIPE No. 2 (MTM)
a. Remove the bolt and oil receiver pipe No. 2 from the manual transmission case.
NOTICE: Be careful not to damage the oil receiver pipe No. 2.
39. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
a. Using a socket hexagon wrench 6, remove the shift detent ball plug from the transaxle case.
b. Using a magnetic finger, remove the shift detent ball spring seat, shift detent ball compression spring and shift detent ball from the transaxle case.
40. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY No. 1
a. Using 2 screwdrivers and a hammer, remove shaft snap ring.
NOTICE: Using a waste to prevent the snap ring from the being scattered.
b. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No. 1.