Part 1

E350 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REMOVAL

REMOVAL

1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Remove the clutch release fork with the clutch release bearing from the transaxle case.
2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
(a) Remove the release bearing and clutch release bearing hub clip from the clutch release fork.

3. REMOVE CLUTCH RELEASE FORK SUPPORT
(a) Remove the clutch release fork support from the 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 hole cover.
(b) Remove the O-ring from the hole cover.

6. REMOVE SELECTING BELLCRANK ASSEMBLY
(a) Remove the 2 bolts and selecting bellcrank assembly from the transmission case.
(b) Remove the shift and select lever bush from the selecting bellcrank.
7. REMOVE CONTROL SHIFT LEVER

(a) Remove the nut and spring washer.

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

8. REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts, control shift cover and gasket from the transmission case.

9. FIX MANUAL TRANSAXLE ASSEMBLY
(a) Place the transaxle on wooden blocks.

10. REMOVE NO. 1 LOCK BALL ASSEMBLY
(a) Remove the lock ball from the transmission case.

11. REMOVE MANUAL TRANSMISSION BREATHER PLUG
(a) Remove the breather plug and gasket.

12. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Remove the shift and select lever shaft from the transmission case.

13. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
(a) Remove the back-up light switch and gasket from the transmission case.

14. REMOVE FILLER PLUG
(a) Remove the filler plug and gasket from the transmission case.

15. REMOVE DRAIN PLUG SUB-ASSEMBLY
(a) Remove the drain plug and gasket from the transmission case.

16. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
(a) Remove the 10 bolts and transmission case cover from the transmission case.
17. REMOVE REAR MANUAL TRANSMISSION OUTPUT SHAFT SET NUT

(a) Engage the 2 gears simultaneously to lock the transmission.

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

18. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 to 0.65 mm (0.0039 to 0.0256 in.)
If the clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

19. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009 to 0.050 mm (0.0004 to 0.0020 in.)
If the clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.
20. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

(a) Using 2 screwdrivers and a hammer, remove the No. 3 transmission clutch hub shaft snap ring from the input shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.

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

(c) Using SST, remove the No. 3 transmission clutch hub, No. 3 transmission hub sleeve 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 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 T45 "TORX" socket, remove the 7 "TORX" screws and bearing retainer from the transmission case.

25. REMOVE OUTPUT SHAFT REAR BEARING SHIM
(a) Remove the rear bearing shim from the output shaft.

26. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
(a) Using a snap ring expander, remove the shaft snap ring from the input shaft.
27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 1 gear shift fork shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.

(b) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 gear shift fork shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.

28. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and gasket.
29. REMOVE CLUTCH TUBE BRACKET
(a) Remove the bolt and clutch tube bracket.
30. REMOVE MANUAL TRANSMISSION CASE

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

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

31. REMOVE NO. 2 OIL RECEIVER PIPE
(a) Remove the bolt and No. 2 oil receiver pipe from the transmission case.
NOTE: Do not damage the pipe.