Part 1

E351 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY





(a) Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.
2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.
3. REMOVE RELEASE FORK SUPPORT





(a) Remove the release fork support from the manual transaxle case.
4. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the manual transaxle case.
5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Remove the bolt and speedometer driven hole cover sub-assembly.
(b) Remove the O-ring.
6. REMOVE SELECTING BELLCRANK ASSEMBLY





(a) Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.
7. REMOVE CONTROL SHIFT LEVER





(a) Remove the nut and spring washer.





(b) Using a brass bar and hammer, remove the shift outer lever lock pin.
(c) Remove the control shift lever.
8. REMOVE CONTROL SHAFT COVER





(a) Remove the 4 bolts and control shaft cover from the manual transmission case.
9. REMOVE NO. 2 CLUTCH TUBE BRACKET





(a) Remove the bolt and No. 2 clutch tube bracket.
10. SECURE MANUAL TRANSAXLE ASSEMBLY





(a) Place the manual transaxle assembly on wooden blocks.
11. REMOVE NO. 1 LOCK BALL ASSEMBLY





(a) Remove the No. 1 lock ball assembly from the manual transmission case.
12. REMOVE SHIFT GATE PIN





(a) Remove the shift gate pin from the manual transmission case.
13. REMOVE MANUAL TRANSMISSION BREATHER PLUG





(a) Remove the manual transmission breather plug.
14. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY





(a) Remove the shift and select lever shaft assembly from the manual transmission case.
15. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY





(a) Remove the back-up light switch assembly and gasket from the manual transmission case.
16. REMOVE MANUAL TRANSMISSION FILLER PLUG





(a) Remove the manual transmission filler plug and gasket from the manual transmission case.
17. REMOVE DRAIN PLUG SUB-ASSEMBLY





(a) Remove the drain plug sub-assembly and gasket from the manual transmission case.
18. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY





(a) Remove the 10 bolts and manual transmission case cover from the manual transmission case.
19. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT





(a) Engage the 1st and 2nd gears simultaneously.





(b) Using SST and a hammer, unstake the manual transmission output shaft rear set nut.
SST: 09930-00010





(c) Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
SST: 09229-55010
(d) Disengage the gears.
20. REMOVE NO. 3 TRANSMISSION CLUTCH HUB





(a) Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.





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





(c) Using SST, remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
SST: 09950-50013
09957-04010
SST: 09950-60010
09951-00280
21. REMOVE 5TH GEAR





(a) Remove the 5th gear from the input shaft.
22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING





(a) Remove the 5th gear needle roller bearing from the input shaft.
23. 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
09957-04010
SST: 09950-60010
09951-00180
09955-03011
SST: 09950-50013
24. REMOVE REAR BEARING RETAINER





(a) Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.
25. REMOVE OUTPUT SHAFT REAR BEARING SHIM





(a) Remove the output shaft rear bearing shim from the output shaft.
26. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING





(a) Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
27. REMOVE SHIFT FORK SHAFT SNAP RING





(a) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.
HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.





(b) Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 2 gear shift fork shaft.
HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.

28. REMOVE REVERSE IDLER GEAR SHAFT BOLT





(a) Remove the reverse idler gear shaft bolt and gasket.
29. REMOVE MANUAL TRANSMISSION CASE





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





(b) Remove the 14 bolts from the manual transmission case.
(c) Tapping with a plastic hammer, remove the manual transmission case.