Manual Transmission Overhaul

Manual Transmission Components 1 1, 3, 9, 12. Plug
2. Transmission Case
4. Oil Tube No. 1
5. Belleville Spring
6. Outer Race
7. Shift Stop Pin
8. Spring Pin
10. Oil Tube No. 2
11. Valve
13. Shift Lever
14. Crankshaft
15. Oil Seal
16. Transmission Case Cover

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Manual Transmission Components 2 1. Output Shaft Front Bearing
2. Output Shaft Sealing Ring
3. Input Shaft Front Bearing
4, 6. Oil Seal
5. Magnet
7. Clutch Release Bearing Retainer
8. Clutch Release Bearing
9. Clutch Release Fork
10. Clutch Release Fork Boot
11. Speed Sensor
12. Speed Sensor Driven Gear
13. Mounting Bracket/Shift Lever Cover
14. Differential Case
15. Accumulator
16. Belleville Spring
17. Axle Bearing Outer Race
18. Differential

Manual Transmission Components 3 1. Synchronizer Sleeve No. 3
2. Synchronizer Hub No. 3
3. Synchronizer Ring
4. 5th Gear
5. Needle Bearing
6. Washer
7. Rear Bearing Retainer
8, 15, 29, 31. Split Snap Ring
9. Input Shaft
10. Output Shaft
11. Idler Gear Shaft
12. Thrust Washer
13. Reverse Idler Gear
14. Reverse Idler Gear Bracket
16. Reverse Shift Fork
17. Shift Fork No. 1
18. Plug
19. Spring Seat
20. Spring
21. Ball
22. Shift Fork Shaft No. 1
23. Shift Fork Shaft No. 3
24. Shift Fork No. 3
25. Tip
26. Shift Fork No. 2
27. Shift Fork Shaft No. 2
28. 5th Gear Driven Gear
29, 31. Split Snap Ring
30. Springs

Overhauling a manual transaxle is a very difficult task for the average home mechanic. It requires disassembly and assembly of a very large number of small parts. It is necessary to maintain very precise clearances and change them, if necessary, by installing new shims or snap rings. Therefore, if the transaxle develops problems, the average home mechanic may remove and install the transaxle, but overhaul should be left to specialists. You can also purchase a rebuilt transaxle; look in the auto market or at repair shops. In any case, the time and money spent on overhauling the transaxle yourself almost always exceed the cost of buying a rebuilt unit.
Nevertheless, a home mechanic who has the necessary equipment can rebuild the transaxle if the work is performed carefully and in sequence.
Tools required for transaxle overhaul include pliers, pullers, a slide hammer, a set of punches, a dial indicator and possibly a hydraulic press. A large, stable workbench and a vise are also required.
When disassembling the transaxle, note the installation position of all components to make assembly easier and more accurate. Diagrams showing the manual transaxle components are provided in this chapter (see Manual Transaxle Components 1, Manual Transaxle Components 2 and Manual Transaxle Components 3).
Before beginning transaxle disassembly, it is advisable to have a general idea of which part of the transaxle has failed. Some problems may be caused by faults in specific areas of the transaxle, which can greatly simplify inspection and replacement of faulty components. Refer to Subsection 1.9 for additional information.