Page 3545 of 5135
C80361
C80362
C80363
C80364
C80365
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±13
C250 M/T REPAIR MANUAL (RM1020E)
34. 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.
35. REMOVE GEAR SHIFT FORK SHAFT NO.1
(a) Using 2 screwdrivers and a hammer, tap out the snap
rings.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(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.
Page 3546 of 5135
C80366
C80367
C80368
C80369
C80586
41±14
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
36. 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:
Using a shop rug to prevent the snap ring from being scattered.
(b) Remove the shift fork shaft No.3, 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:
Using a shop rug to prevent the snap ring from being scattered.
(e) Remove the reverse shift fork from the gear shift fork shaft
No.3.
37. REMOVE INPUT SHAFT ASSY
(a) Remove the input shaft assy and output shaft assy from
the front transaxle case.
Page 3547 of 5135
C67656
C67657
D30546
D30547
C67644
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±15
C250 M/T REPAIR MANUAL (RM1020E)
38. REMOVE DIFFERENTIAL CASE ASSY
(a) Remove the differential case assy from the front transaxle
case.
39. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the bolt and manual transaxle case receiver from
the front transaxle case.
40. 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 hammer, drive out the
slotted spring pin and reverse restrict pin assy from the
manual transmission case.
41. 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.
Page 3548 of 5135
C80374
C67658
C67659
C81783
SST
C81783
SST
41±16
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
42. 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.
43. REMOVE BEARING LOCK PLATE
(a) Remove the bolt and bearing lock plate from the front
transaxle case.
44. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the front transaxle
case.
45. 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)
46. 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)
Page 3549 of 5135

C82141
SST
C67719
C81785
SST
C82145
SST
C81789
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±17
C250 M/T REPAIR MANUAL (RM1020E)
47. 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 unreasonable force to the front transaxle case
when installing it.
48. REMOVE OUTPUT SHAFT (MTM) COVER
(a) Remove the output shaft cover from the front transaxle
case.
49. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing (outer race) and shim from the front
transaxle case.
SST 09612±65014 (09612±01040, 09612±01050),
(b) Using SST, remove the front differential case front ta-
pered roller bearing (inner race) from the front differential
case.
SST 09950±00020, 09950±00030, 09950±40011
(09957±04010), 09950±60010 (09951±00360)
NOTICE:
Be careful not to damage bearing.
50. 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)
Page 3550 of 5135

C81788
SST
C82144
SST
C81787
SST
D30571
SST
C67848
41±18
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
51. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing (outer race) and shim from the transmission
case.
SST 09612±65014 (09612±01040, 09612±01050)
(b) Using SST and hammer, 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 bearing.
52. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST and hammer, drive out the transmission case
oil seal from the manual transmission case.
SST 09950±60010 (09951±00600), 09950±70010
(09951±07100)
53. REMOVE SHIFT & SELECT LEVER SHAFT NEEDLE
ROLLER BEARING
(a) Using SST, remove the shift & select lever shaft needle
roller bearing.
SST 09319±60020
54. INSPECT SYNCHRONIZER RING NO.3
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone, check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
Page 3551 of 5135

C67850
C67978
C80375
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±19
C250 M/T REPAIR MANUAL (RM1020E)
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the breaking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0649 in.)
Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than minimum, replace the synchronizer
ring and gear cone by applying a small amount of the fine lap-
ping compound.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
55. INSPECT TRANSMISSION HUB SLEEVE NO.3
(a) Check the sliding condition between the transmission hub
sleeve No.3 and transmission clutch hub No.3.
(b) Check that spline gear's of the transmission hub sleeve
No.3 is not worn down.
(c) Using a vernier calipers, inspect the transmission hub
sleeve No.3 and gear shift fork No.3 as shown in the il-
lustration.
Standard clearance:
0.3 ± 0.5 mm (0.0012 ± 0.0020 in.)
If the clearance exceeds the standard clearance, replace the
transmission hub sleeve No.3 and gear shift fork No.3.
Page 3552 of 5135

C67975
C67846
C67719
C80376
SST 41±20
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
56. INSPECT 5TH GEAR
(a) Using a caliper gauge, inspect 5th gear as shown in the
illustration.
Standard clearance:
29.915 ± 29.931 mm (1.1778 ± 1.1783 in.)
If the clearance exceeds the maximum, replace the 5th gear.
57. INSPECT REVERSE IDLER GEAR SUB±ASSY
(a) Using a caliper gauge, inspect the reverse idler gear sub±
assy as shown in the illustration.
Standard clearance:
18.040 ± 18.058 mm (0.7102 ± 0.7109 in.)
Maximum clearance:
18.058 mm (0.7109 in.)
If the clearance exceeds the maximum, replace idler gear.
(b) Using a micrometer, inspect the reverse idler gear shaft
as shown in the illustration.
Standard outer diameter:
17.966 ± 17.984 mm (0.7073 ± 0.7080 in.)
Minimum outer diameter:
17.966 mm (0.7073 in.)
If the outer diameter exceeds the minimum, replace the reverse
idler gear shaft.
58. INSTALL OUTPUT SHAFT (MTM) COVER
(a) Coat the output shaft cover with MP grease and install it
to the front transaxle case.
59. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Coat the new output shaft front bearing with gear oil, us-
ing SST and a press, install it.
SST 09950±60010 (09951±00550), 09950±70010
(09951±07150)
NOTICE:
Be careful not to damage the output shaft front bearing.