Page 3537 of 5135
C67604
D30525
D30526
SST
D30527
D30528
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±5
C250 M/T REPAIR MANUAL (RM1020E)
6. REMOVE RELEASE FORK SUPPORT
(a) Remove the clutch release fork support from the front
transaxle case.
7. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the front trans-
axle case.
8. REMOVE BACK UP LAMP SWITCH ASSY
(a) Using SST, remove the back±up lamp switch assy and
gasket from the manual transmission case.
SST 09817±16011
9. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING
SUPPORT BRACKET
(a) Remove the 3 bolts and control cable bracket from the
front transaxle case.
10. REMOVE SELECTING BELL CRANK ASSY
(a) Remove the 2 bolts and selecting bell crank assy from the
manual transmission case.
Page 3538 of 5135
D30530
D30531
D30532
D30533
D30534
41±6
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
11. REMOVE LOCK BALL ASSY NO.1
(a) Remove the lock ball assy No.1 from the manual trans-
mission case.
12. REMOVE CONTROL SHIFT LEVER
(a) Remove the nut and spring washer.
(b) Using a brass bar and a hammer, remove the shift outer
lever lever lock pin.
(c) Remove the control shift lever.
13. REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts, control shaft cover and gasket from
the manual transmission case.
14. REMOVE SHIFT & SELECT LEVER SHAFT ASSY
(a) Remove the shift & select lever shaft assy from the manu-
al transmission case.
Page 3539 of 5135
D30529
C80554
C80555
C80341
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±7
C250 M/T REPAIR MANUAL (RM1020E)
15. FIX MANUAL TRANSAXLE ASSY
(a) Using 2 wooden blocks, fixing the manual transaxle assy.
16. REMOVE MANUAL TRANSMISSION CASE COVER
SUB±ASSY
(a) Remove the 9 bolts.
(b) Carefully tap the projection of the manual transmission
case cover sub±assy with a hammer and remove it.
NOTICE:
Do not damage the manual transmission case sub±assy.
17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT
REAR SET NUT
(a) Using a chisel and a hammer, loosen the staked part of
the manual transmission output shaft rear set nut.
Page 3540 of 5135
Q06512
D30535
C80343
C80344
C80345
41±8
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
(b) Engage the gear to the double meshing.
(c) Remove the manual transmission output shaft rear set
nut.
(d) Disengage the double meshing of the gear.
18. REMOVE GEAR SHIFT FORK NO.3
(a) Remove the shift fork set bolt from the gear shift fork
No.3.
(b) Remove the No.3 hub sleeve and gear shift fork No.3 from
the transmission clutch hub No.3.
19. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 ± 0.57 mm (0.0039 ± 0.0224 in.)
Maximum clearance:
0.57 mm (0.0224 in.)
20. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the gear needle
roller bearing or shaft.
Page 3541 of 5135

D30536
C80347
SST
D07737
D30537
D30538
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±9
C250 M/T REPAIR MANUAL (RM1020E)
21. REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Using SST, remove the transmission clutch hub No.3, 5th
gear and synchronizer ring from the input shaft.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04030, 09954±04010, 09955±04071,
09957±04010), 09950±60010 (09951±00200)
(c) Remove the 3 synchromesh shifting keys and 2 synchro-
mesh shifting key springs from the transmission clutch
hub No.3.
22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing and 5th gear
bearing spacer 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, 09955±03011, 09957±04010),
09950±60010 (09951±00190)
Page 3542 of 5135
D30539
C80351
C80352
D30540
C80353
41±10
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
24. REMOVE BEARING RETAINER REAR (MTM)
(a) Remove the 5 bolts and bearing retainer rear from the
manual transmission case.
25. REMOVE OUTPUT SHAFT REAR BEARING HOLE
SNAP RING
(a) Using a snap ring expander, remove the output shaft rear
bearing hole snap ring from the output shaft.
26. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP
RING
(a) Using a snap ring expander, remove the input shaft rear
bearing hole snap ring from the input shaft.
27. 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.
28. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to the shifting key spring from being scattered.
Page 3543 of 5135
C67634
C67635
D30541
D30542
D30543
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±11
C250 M/T REPAIR MANUAL (RM1020E)
29. 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.
30. REMOVE LOCK BALL ASSY NO.2
(a) Using a hexagon wrench, remove the lock ball assy No.2
from the manual transmission case.
Page 3544 of 5135
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C80358
C67642
C80359
C80360
41±12
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
31. 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) Carefully tap the transmission case with a brass bar and
hammer and remove it from the transaxle case.
32. REMOVE REVERSE IDLER GEAR SUB±ASSY
(a) Remove the revers idler gear, thrust washer and reverse
idler gear shaft from the front transaxle case.
33. REMOVE REVERSE SHIFT ARM BRACKET ASSY
(a) Remove the 2 bolts and reverse shift arm bracket assy
from the front transaxle case.