Tools Required

1. Remove the manual transaxle. Refer to Transmission Replacement .
2. Remove the related clutch parts. Refer to Clutch, Pressure Plate, and Pilot Bearing Replacement in Clutch.



3. Remove the manual transaxle bolts (1, 3) and nut (2).
4. Remove the mounting bracket (2).



5. Disconnect the backup light switch connector (4) and remove the backup light switch (1).
6. Disconnect the speedometer driven gear assembly cable.
7. Remove the speedometer driven gear assembly (2).

Important:  Remove the shift interlock bolt. Otherwise, the gear shift control case cannot be removed.

8. Remove the shift interlock bolt.



9. Remove the side cover bolts (1).
10. Remove the side cover using a rubber hammer (2).
11. Remove the sealant on the side cover and the transaxle case.



12. Remove the 5th gear shift fork plug (1).
13. Remove the guide ball using a magnet.
14. Remove the 5th gear shift fork snap ring (2).
15. Remove the 5th gear snap ring (3).
16. Remove the 5th gear synchronizer plate.



17. Shift the shift fork to the 5th gear.
18. Remove the 5th gear fork pin using a pin punch and a hammer (1).



19. Pull and remove the fork and the synchronizer hub assembly together (1).
20. Remove the sleeve, key and spring from the synchronizer hub assembly.



21. Pull and remove the 5th gear, wave spring and synchronizer ring together (1).
22. Remove the 5th gear bearing.



23. Remove the countershaft 5th gear caulking and the nut (1).
24. Remove the counter shaft 5th gear (1).



25. Remove the side cover screws (1) and plate (2).
26. Remove the counter shaft bearing shim.



27. Remove the bolt and remove the 5th reverse gear shift shaft spring and ball (3).
28. Remove the bolt and remove the 3rd-4th gear shift shaft spring and ball (1).

Important:  There is difference between the 5th reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.

29. Remove the bolt and remove the 1st-2nd gear shift shaft spring and ball (2).




Important:  The case-Left, cannot be removed without removing the reverse idle gear shaft bolt.

30. Remove the reverse idle gear shaft bolt.



31. Remove the transaxle case bolts from the left side case.
32. Remove the transaxle case bolts from the right side of case.
33. Remove the left side case by hitting with a rubber hammer lightly.
34. Remove the sealant on the case.



35. Remove the reverse gear shift lever bolts (1) and lever (2).



36. Push the reverse idle gear toward inner case.
37. Pull the shaft and remove the reverse idle gear and shaft (1).
38. Remove the reverse idle gear from the shaft.



39. Remove the 5th reverse gear shift shaft (1).



40. Remove the shift and select lever and outer pins.



41. Remove the gear shift and select shaft (4).
42. Remove the gear select spring assembles (2).
43. Remove the gear shift interlock plate (9).
44. Remove the gear shift lever (8).
45. Remove the 5th and reverse gear shift cam (3) and return spring (7).
46. Remove the shift and select bellows (5).
47. Remove the shift and select shaft oil seal (6).



48. Remove the shift and select shaft needle bearings using needle bearing remover DT 47515  (1) .




Important: Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

49. Remove the gear unit and the shift shaft assembly together (1).
50. Remove the high and the low speed shift shaft assembly from the gear unit.



51. Insert a wooden stick into the lower side of differential (1).
52. Remove the differential assembly by moving it right and left (2).
53. Remove the counter shaft RH bearing (1).



54. Remove the oil gutter bolt (1) and gutter (2).
55. Remove the differential left side oil seal using a hammer and a copper chisel (4).



56. Remove the oil level plug (2).
57. Remove the case cap, left side, bolts and cap.
58. Remove the case cap O-ring, left side.
59. Remove the counter shaft bearing outer race using a hammer and the gear, bearing installer DT 46496 .



60. Remove the input shaft oil seal using a screwdriver (2).
61. Remove the differential left side oil seal using a hammer and a copper chisel (1).