Disassembly

EB60 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: DISASSEMBLY

1. REMOVE MANUAL TRANSMISSION FILLER PLUG

(a) Remove the manual transmission filler plug and gasket from the manual transmission case sub-assembly.

2. REMOVE MANUAL TRANSMISSION DRAIN PLUG

(a) Remove the manual transmission drain plug and gasket from the front transaxle case.

3. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, remove the back-up light switch and gasket from the manual transmission case sub-assembly.

SST : 09817-16011

4. REMOVE TRANSMISSION CASE PLUG

(a) Remove the transmission case plug and gasket from the manual transmission case sub-assembly.

5. REMOVE CONTROL CABLE BRACKET ASSEMBLY

(a) Remove the 3 bolts and control cable bracket assembly from the manual transmission case sub-assembly.

6. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

7. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY Removal

8. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY Removal

9. REMOVE BLEEDER CLUTCH RELEASE TUBE Removal

10. SECURE MANUAL TRANSAXLE ASSEMBLY

(a) Place the manual transaxle assembly on wooden blocks.

11. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket from the manual transmission case sub-assembly.

12. REMOVE LOCK BALL PIN

(a) Using a 10 mm hexagon socket wrench, remove the 2 shift and select lever shaft straight screw with head plugs from the manual transmission case sub-assembly.

(b) Using a magnet hand, remove the 2 shift and select lever shaft compression springs and 2 lock ball pins from the manual transmission case sub-assembly.

13. REMOVE SHIFT DETENT BALL

(a) Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the manual transmission case sub-assembly.

(b) Using a magnet hand, remove the shift detent ball compression spring and shift detent ball from the manual transmission case sub-assembly.

(c) Using a 6 mm hexagon socket wrench, remove the 2 shift detent ball plugs from the manual transmission case sub-assembly.

(d) Using a magnet hand, remove the 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case sub-assembly.

14. REMOVE OUTER SHIFT LEVER E-RING

(a) Remove the outer shift lever E-ring from the outer No. 1 shift lever.

15. REMOVE MANUAL TRANSMISSION CASE SUB-ASSEMBLY

(a) Remove the 17 bolts.

(b) Using a screwdriver with its tip wrapped with protective tape, separate the manual transmission case from the front transaxle case.

Text in Illustration

NOTICE:
Do not damage the manual transmission case sub-assembly.

(c) Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.

(d) Push the outer No. 1 shift lever and remove the manual transmission case sub-assembly.

16. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Remove the reverse idler gear shaft, reverse idler thrust washer and reverse idler gear sub-assembly from the front transaxle case.

17. REMOVE REVERSE SHIFT FORK

(a) Turn the reverse shift fork clockwise and remove it from the front transaxle case.

(b) Using a 5 mm pin punch and hammer, tap out the reverse shift fork slotted spring pin.

(c) Remove the reverse shift fork from the No. 4 gear shift fork shaft assembly.

18. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Using a 6 mm hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.

19. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the inner select lever set bolt.

(b) Turn the shift and select lever shaft assembly clockwise and remove the shift and select lever shaft assembly and shift interlock plate from the front transaxle case.

20. REMOVE OUTER SELECT LEVER

(a) Remove the outer select lever and inner select lever from the front transaxle case.

21. REMOVE OUTER SELECT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the front transaxle case.

Text in Illustration

NOTICE:
Do not damage the installation surfaces.

22. REMOVE INPUT SHAFT ASSEMBLY AND OUTPUT SHAFT ASSEMBLY

(a) Remove the input shaft assembly together with the output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.

(b) Remove the output shaft assembly together with the No. 1 gear shift fork shaft assembly from the input shaft assembly.

(c) Remove the No. 1 gear shift fork shaft assembly from the output shaft assembly.

(d) Remove the No. 2 gear shift fork shaft assembly from the input shaft assembly.

23. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the differential case from the front transaxle case.

24. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST, tap out the front differential case front tapered roller bearing (outer race) and front differential oil baffle from the front transaxle case.

SST : 09308-00010

(b) Using SST, remove the differential case front tapered roller bearing from the differential case assembly.

Text in Illustration

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00350

09951-00550

09952-06010

25. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST, tap out the front differential case rear tapered roller bearing (outer race) and front differential case rear plate shim from the manual transmission case sub-assembly.

SST : 09308-00010

(b) Using SST, remove the front differential case rear tapered roller bearing from the front differential case assembly.

Text in Illustration

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04021

09957-04010

09958-04011

SST : 09950-60010

09951-00350

09951-00550

09952-06010

26. REMOVE TRANSMISSION MAGNET

(a) Remove the transmission magnet from the front transaxle case.

27. REMOVE BREATHER PLUG

(a) Remove the breather plug from the front transaxle case.

28. REMOVE FRONT OUTPUT SHAFT BEARING

(a) Using SST, tap out the front output shaft bearing (outer race) from the front transaxle case.

SST : 09308-00010

(b) Remove the output shaft cover from the front transaxle case.

29. REMOVE FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST, tap out the front transaxle case oil seal from the front transaxle case.

SST : 09950-60010

09951-00360

SST : 09950-70010

09951-07150

30. REMOVE STRAIGHT PIN

(a) Remove the 5 straight pins from the front transaxle case.

31. REMOVE REAR INPUT SHAFT BEARING SHIM

(a) Remove the rear input shaft bearing shim from the manual transmission case sub-assembly.

32. REMOVE INPUT SHAFT COVER

(a) Remove the input shaft cover from the manual transmission case sub-assembly.

33. REMOVE MANUAL TRANSMISSION CASE RECEIVER

(a) Remove the manual transmission case receiver from the manual transmission case sub-assembly.

34. REMOVE OUTER NO. 1 SHIFT LEVER

(a) Using a 5 mm pin punch and hammer, tap out the inner shift lever slotted spring pin.

HINT
When removing the slotted spring pin, align the pin with the hole in the lock ball assembly.

(b) Remove the inner No. 1 shift lever, No. 1 shift lever shaft housing washer and outer No. 1 shift lever from the manual transmission case sub-assembly.

35. REMOVE OUTER SHIFT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the manual transmission case sub-assembly.

Text in Illustration

NOTICE:
Do not damage the installation surfaces.

36. REMOVE REAR OUTPUT SHAFT BEARING

(a) Using SST, tap out the rear output shaft bearing (outer race) and rear output shaft bearing shim from the manual transmission case sub-assembly.

SST : 09308-00010

37. REMOVE TRANSAXLE CASE OIL SEAL

(a) for LH Side:

(1) Using SST, tap out the transaxle case oil seal from the manual transmission case sub-assembly.

SST : 09308-00010

(b) for RH Side:

(1) Using SST, tap out the transaxle case oil seal from the front transaxle case.

SST : 09308-00010