Part 2

MANUAL TRANSAXLE ASSY (C50)
OVERHAUL





26. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a. Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case.





27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: Use a shop rag to keep the shifting key spring from flying.





28. REMOVE SHIFT DETENT BALL
a. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.





b. Using a magnetic finger, remove the 2 seats, springs and balls from the manual transmission case.





c. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.





d. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.





29. REMOVE LOCK BALL ASSY NO.2
a. Using a hexagon wrench, remove the lock ball assy No.2 from the manual transmission case.





30. REMOVE MANUAL TRANSMISSION CASE
a. Remove the 3 bolts from the front transaxle case.





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





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





31. REMOVE REVERSE IDLER GEAR SUB-ASSY
a. Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.





32. REMOVE REVERSE SHIFT ARM BRACKET ASSY
a. Remove the 2 bolts and reverse shift arm bracket assy from the front transaxle case.





33. REMOVE GEAR SHIFT FORK SHAFT NO.2
a. Remove the 2 bolts from the gear shift fork No.2 and gear shift head No.1.





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





34. REMOVE GEAR SHIFT FORK SHAFT NO.1
a. Using 2 screwdrivers and a hammer, tap out the snap rings.

HINT: Use a shop rag to keep the snap ring from flying.





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





c. Remove the shift fork No.1.





35. REMOVE GEAR SHIFT FORK SHAFT NO.3
a. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No.3.

HINT: Use a shop rag to keep the snap ring from flying.





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





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





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

HINT: Use a shop rag to keep the snap ring from flying.

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





36. REMOVE INPUT SHAFT ASSY
a. Remove the input shaft assy and output shaft assy from the front transaxle case.





37. REMOVE DIFFERENTIAL CASE ASSY
a. Remove the differential case assy from the front transaxle case.





38. REMOVE MANUAL TRANSAXLE CASE RECEIVER
a. Remove the bolt and manual transaxle case receiver from the front transaxle case.





39. REMOVE REVERSE RESTRICT PIN ASSY
a. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.





b. Using a pin punch (5 mm) and a hammer, drive out the slotted spring pin and reverse restrict pin assy from the manual transmission case.





40. 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.





41. 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.





42. REMOVE BEARING LOCK PLATE
a. Remove the bolt and bearing lock plate from the front transaxle case.





43. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the front transaxle case.





44. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST, remove the input shaft front bearing from the front transaxle case.
SST 09612-65014 (09612-01050, 09612-01060)





45. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using SST, remove the front transaxle case oil seal from the front transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





46. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing from the front transaxle case.
SST 09308-00010

NOTICE: Do not apply excessive force to the front transaxle case when installing it.





47. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output shaft cover from the front transaxle case.





48. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. 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)





b. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)

NOTICE: Be careful not to damage the bearing.





49. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and hammer, remove the transaxle case oil seal from the front transaxle case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)





50. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
SST 09612-65014 (09612-01040, 09612-01050)





b. 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)

NOTICE: Be careful not to damage the bearing.