Disassembly
Precaution1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
WARNING Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air, and verify that there are no obstructions.
5th/Reverse Gear and Housing Parts
1. Measure the 5th gear thrust clearance, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
1. Rear cover
2. Locknut (primary shaft)
3. Locknut (secondary shaft)
4. Primary reverse synchronizer gear
5. Reverse synchronizer ring
6. Secondary reverse synchronizer gear
7. 5th/reverse shift fork
8. 5th/reverse clutch hub assembly
9. 5th synchronizer ring
10. 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Lock bolt
14. Guide bolt
15. Look bolt, ball and spring
16. Back-up light switch
17. Neutral switch
18. Transaxle case assembly
19. Magnet
20. Reverse idler shaft
21. Reverse idler gear
22. 5th/reverse shift rod
23. 5th/reverse shift rod end
24. Pin
25. Crank lever shaft
26. Crank lever assembly
27. Shift fork and shift rod assembly
28. Steel ball
29. Spring
30. Primary shaft gear assembly
31. Secondary shaft gear assembly
32. Differential assembly
33. Clutch housing
34. Synchronizer key spring
35. Clutch hub sleeve
36. Synchronizer key
37. Clutch hub
38. 3rd/4th shift fork
39. Interlock sleeve
40. Control lever
41. 1st/2nd shift fork
42. Control rod
43. Control end
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance by using a dial indicator.
Clearance: 0.10-0.22 mm (0.004-0.009 in)
Maximum: 0.27 mm (0.011 in)
2. If the clearance exceeds the maximum, check the contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly note
Locknut
1. Mount the transaxle on the SSTs.
2. Lock the primary shaft by using the SST.
3. Shift to 1st gear to lock the rotation of the primary shaft.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control lever (arrow). Turn the shift rod counterclockwise.
2. While holding the 1st/2nd shift fork with one hand and the 3rd/4th shift fork with the other, raise them both at the same time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the same time, remove the control rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each of the clutch hub sleeves.
Clutch Housing and Transaxle Case Components
NOTE: The oil seals do not need to be removed unless they are being replaced.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Oil seal (primary shaft)
CAUTION: The clutch housing is made of aluminum, and is therefore easily dented and scratched by metal tools. When removing the oil seal, keep contact with the clutch housing to a minimum.
Remove the oil seal from the clutch housing as shown in the image.
Bearing race (secondary shaft)
Remove the bearing race by lifting it and the funnel out together.
Roll pin
To remove the clutch housing pin, align the groove with the roll pin, then tap the pin out by using a pin punch.
Oil seal (change rod assembly)
Remove the oil seal.
Oil seal (differential)
Remove the oil seal.
Bearing race (differential)
Remove the bearing outer race by using the SST.
Reverse lever shaft
1. Remove the roll pin by using pliers.
2. Protect the reverse lever shaft with a rag, and use pliers to remove the shaft.
Bearing race (transaxle case)
Remove the bearing race by using the SST.
Primary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
Preinspection
3rd gear thrust clearance
1. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.05-0.20 mm (0.002-0.008 in)
Maximum: 0.25 mm (0.010 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 3rd gear, 2nd gear and clutch hub (3rd/4th). Replace worn and damaged pans.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball bearing.
Clearance: 0.17-0.37 mm (0.007-0.015 in)
Maximum: 0.42 mm (0.017 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 4th gear, ball bearing, and clutch hub (3rd/4th). Replace worn and damaged parts.
Disassembly note
Bearing (4th gear end)
Remove the bearing by using the SST
3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear
1. Remove the retaining ring.
2. Remove the 3rdl4th clutch hub assembly, 3rd synchronizer ring , and 3rd gear by using the SST.
Bearing (primary shaft end)
Remove the bearing by using the SST
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
Preinspection
1st gear thrust clearance
1. Measure the clearance between 1st gear and the differential drive gear.
Clearance: 0.05-0.28 mm (0.002-0.011 in)
Maximum: 0.33 mm (0.013 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 1st gear, differential drive gear of the secondary shaft gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary 3rd gear.
Clearance: 0.18-0.46 mm (0.007-0.018 in)
Maximum: 0.51 mm (0.020 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.
Disassembly note
Bearing and secondary 4th gear
Remove the bearing and secondary 4th gear by using the SST.
Secondary 3rd gear and 2nd gear
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear by using the SST.
1st/2nd clutch hub assembly, 1st synchronizer ring, and 1st gear
1. Remove the retaining ring.
2. Remove the 1st/2nd clutch hub assembly, 1st synchronizer ring , and 1st gear by using a press.
Bearing (secondary shaft end)
Remove the bearing by using the SSTs.