Manual Transaxle ASSY (E351): Overhaul

1. Remove the clutch release fork with clutch release bearing from the manual transaxle case.
   Fig 1: Removing Clutch Release Fork With Clutch Release Bearing From Manual Transaxle Case

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

1. Remove the release fork support from the manual transaxle case.
   Fig 2: Removing Release Fork Support From Manual Transaxle Case

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

1. Remove the bolt and speedometer driven hole cover.

1. Remove the 2 bolts and selecting bell crank assy from manual transmission case.
   Fig 3: Removing Selecting Bell Crank Assy From Manual Transmission Case

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1. Remove the nut and spring washer.
   Fig 4: Removing Nut And Spring Washer From Control Shift Lever

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2. Using a brass bar and hammer, remove the shift outer lock pin.
3. Remove the control shift lever.
   Fig 5: Removing Control Shift Lever

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1. Remove the 4 bolts and control shaft cover from the manual transmission case.
   Fig 6: Removing Control Shaft Cover From Manual Transmission Case

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1. Using wooden blocks, fix the manual transaxle assy.
   Fig 7: Using Wooden Blocks To Support Manual Transaxle Assy

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1. Remove the lock ball assy No. 1 from the manual transmission case.
   Fig 8: Removing Lock Ball Assy No. 1 From Manual Transmission Case

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1. Remove the manual transmission breather plug and gasket.
   Fig 9: Removing Manual Transmission Breather Plug & Gasket

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1. Remove the shift & select lever shaft assy from the manual transmission case.
   Fig 10: Removing Shift & Select Lever Shaft Assy From Manual Transmission Case

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1. Remove the back up lamp switch assy and gasket from the manual transmission case.
   Fig 11: Removing Back Up Lamp Switch Assy & Gasket From Manual Transmission Case

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1. Remove the manual transmission filler plug and gasket from the manual transmission case.
   Fig 12: Removing Manual Transmission Filler Plug & Gasket From Manual Transmission Case

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1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
   Fig 13: Removing Drain (MTM) Plug Sub-Assy & Gasket From Manual Transmission Case

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1. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
   Fig 14: Removing Bolts & Manual Transmission Case Cover From Manual Transmission Case

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1. Engage the gear to the double meshing.
   Fig 15: Engaging Gear To Double Meshing

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

   SST 09930-00010

   Fig 16: Using SST & Hammer To Loosen Staked Part Of Manual Transmission Output Shaft Rear Set Nut

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3. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.

   SST 09229-55010

4. Disengage the double meshing of the gear.
   Fig 17: Using SST To Remove Manual Transmission Output Shaft Rear Set Nut From Output Shaft

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

   Standard clearance: 

   0.10 to 0.65 mm (0.0039 to 0.0256 in.) 

   Fig 18: Using Dial Indicator To Inspect 5th Gear Thrust Clearance

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1. Using a dial indicator, inspect the 5th gear radial clearance.

   Standard clearance: 

   0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

HINT:

If the clearance is out of the specification, replace 1st gear needle roller bearing.

Fig 19: Using Dial Indicator To Inspect 5th Gear Radial Clearance

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1. Using 2 screwdrivers and hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.

   HINT:

   Using a waste to prevent the snap ring from being scattered.

   Fig 20: Using Screwdrivers & Hammer To Remove Transmission Clutch Hub No. 3

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2. Remove the gear shift fork bolt from the gear shift fork No. 3.
   Fig 21: Removing Gear Shift Fork Bolt From Gear Shift Fork No. 3

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3. Using SST, remove the transmission clutch hub No. 3 and gear shift fork No. 3 from the input shaft.

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)

   Fig 22: Using SST To Remove Transmission Clutch Hub No. 3 & Gear Shift Fork No. 3 From Input Shaft

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1. Remove the 5th gear from the input shaft.
   Fig 23: Removing 5th Gear From Input Shaft

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1. Remove the 5th gear needle roller bearing from the input Shaft.
   Fig 24: Removing 5th Gear Needle Roller Bearing From Input Shaft

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1. Using SST, remove the 5th driven gear from the output shaft.

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013

   Fig 25: Using SST To Remove 5th Driven Gear From Output Shaft

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1. Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.
   Fig 26: Using TORX Socket Wrench (T45) To Remove TORX Screws & Bearing Retainer Rear (MTM) From Manual Transmission Case

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1. Remove the output shaft rear bearing shim from the output shaft.
   Fig 27: Removing Output Shaft Rear Bearing Shim From Output Shaft

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1. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
   Fig 28: Using Snap Ring Expander To Remove Input Shaft Rear Bearing Shaft Snap Ring From Input Shaft

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

   HINT:

   Using a waste to prevent the snap ring from being scattered.

   Fig 29: Using Screwdrivers & Hammer To Remove Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 1

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2. Using 2 screw drivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 2.

   HINT:

   Using a waste to prevent the snap ring from being scattered.

   Fig 30: Using Screw Drivers & Hammer To Remove Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 2

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1. Remove the reverse idler gear shaft bolt and gasket.
   Fig 31: Removing Reverse Idler Gear Shaft Bolt & Gasket

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1. Remove the 3 bolts and remove the clutch tube bracket.

1. Remove the 3 bolts of the manual transaxle case side.
   Fig 32: Removing Bolts Of Manual Transaxle Case Side

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2. Remove the 14 bolts of the manual transmission case side.
3. Using a plastic hammer, remove the manual transmission case.
   Fig 33: Removing Bolts Of Manual Transmission Case Side

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