БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ 'MULTIMODE' > РАЗБОРКА

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

1. Remove the drain plug and gasket from the manual transmission case.
   

1. Remove the bolt and the speedometer driven hole cover.
   

2. Remove the O-ring from the speedometer driven hole cover.
   

1. Remove the clutch release fork with the clutch release bearing from the front transaxle case.
   

1. Remove the release bearing hub clip and the clutch release bearing from the clutch release fork.
   

1. Remove the clutch release fork support boot from the release fork support.
   

1. Remove the release fork support from the front transaxle case.
   

1. Remove the clutch release fork boot from the front transaxle case.
   

1. Remove the 2 bolts and transmission case protector.
   

2. Remove the transmission revolution sensor from the manual transmission case.
   

3. Remove the O-ring from the transmission revolution sensor.
   

1. Using SST, remove the back up light switch and gasket from the manual transmission case.
   

   SST

   09817-16011  
   

1. Using SST, remove the neutral position switch and gasket from the manual transmission case.
   

   SST

   09817-16011  
   

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

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

2. While looking through the plug, check that the slit in the shift and select shaft is as shown in the illustration.
   If not, turn and adjust it with a screwdriver.
   

3. Remove the 6 bolts, wire harness clamp bracket and shift and select actuator from the manual transmission case.
   

1. Using 2 wooden blocks, fix the manual transaxle assembly.
   

1. Remove the 9 bolts and 2 wire harness clamps.
   

2. Gently tap the protrusion of the manual transmission case cover with a hammer and remove it.
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the manual transmission case.

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

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

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

4. Disengage the double meshing of the gear.
   

1. Remove the shift fork set bolt from No. 3 gear shift fork.
   

2. Remove No. 3 hub sleeve and No. 3 gear shift fork from No. 3 transmission clutch hub.
   

1. Using a dial indicator, measure the 5th gear thrust clearance.
   

   Standard clearance:

   0.10 to 0.57 mm (0.0039 to 0.0224 in.)
   

   Maximum clearance:

   0.57 mm (0.0224 in.)
   

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

1. Using a dial indicator, measure the 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.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring.
   

   УКАЗАНИЕ:

   Use a shop rag or piece of cloth to keep the snap ring from flying off.

2. Remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.
   

3. Using SST, remove the No. 3 transmission clutch hub, 5th gear and No. 3 synchronizer ring from the input shaft.
   

   SST

   09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05031, 09957-04010)
   09950-60010   (09951-00200)
   

4. Remove the 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring from the No. 3 transmission clutch hub.
   

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

1. 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, 09952-06010)
   

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

1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
   

1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
   

1. Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring.
   

   УКАЗАНИЕ:

   Use a shop rag or piece of cloth to keep the snap ring from flying off.

1. Using a hexagon wrench, remove the shift detente ball plug from the manual transmission case.
   

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

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

2. Remove the 13 bolts from the manual transmission case.
   

3. Gently tap the manual transmission case with a brass bar and a hammer and remove it from the front transaxle case.
   

   ПРИМЕЧАНИЕ:

   Do not damage the manual transmission case or front transaxle case.

4. Remove the 4 manual transmission case straight pins from the front transaxle case.
   

1. Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.
   

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

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

2. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the front transaxle case.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring.
   

   УКАЗАНИЕ:

   Use a shop rag or piece of cloth to keep the snap ring from flying off.

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

3. Remove the No. 1 gear shift fork.
   

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
   

   УКАЗАНИЕ:

   Use a shop rag or piece of cloth to keep the snap ring from flying off.

2. Remove the No. 3 shift fork shaft with reverse shift fork and No. 2 gear shift fork from the front transaxle case.
   

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

4. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 shift fork shaft.
   

   УКАЗАНИЕ:

   Use a shop rag or piece of cloth to keep the snap ring from flying off.

5. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
   

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

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

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

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

2. Using a pin punch (φ 5 mm) and a hammer, drive the slotted spring pin and reverse restrict pin out of the manual transmission case.
   

1. Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the No. 1 oil receiver pipe.

1. Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the No. 2 oil receiver pipe.

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

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

1. Using SST, remove the input shaft front bearing from the front transaxle case.
   

   SST

   09612-65014   (09612-01050, 09612-01060)
   

1. Using SST, remove the front transaxle case oil seal from the front transaxle case.
   

   SST

   09612-65014   (09612-01040, 09612-01050)
   

1. Using SST, remove the output shaft front bearing from the front transaxle case.
   

   SST

   09308-00010  
   

   ПРИМЕЧАНИЕ:

   Do not apply excessive force to the front transaxle case when removing the output shaft front bearing.

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

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)
   

2. Using SST, remove the front 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)
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the bearing.

1. Using a screwdriver and a hammer, drive the transmission case oil seal out of the manual transmission case.
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the manual transmission case.

1. Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the manual transmission case.
   

   SST

   09950-60010   (09951-00620)
   09950-70010   (09951-07200)
   

2. 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)
   

   ПРИМЕЧАНИЕ:

   Be careful not to damage the bearing.

1. Using SST and a hammer, drive the transaxle case oil seal out of the front transaxle case.
   

   SST

   09950-60010   (09951-00600)
   09950-70010   (09951-07100)