Disassembly and Reassembly
MANUAL TRANSAXLE ASSEMBLYComponents
Disassembly
1. Remove the rear cover bolts and rear cover.
2. Remove the backup light switch, gasket and mounting bracket.
3. Remove the poppet plugs, poppet springs and poppet balls.
4. Remove the speedometer driven gear assembly.
5. Remove the spring pin using the special tool (09414-11000).
6. Removal of the lock nuts
1) Unstake lock nuts of the input shaft and intermediate shaft.
2) Shift the transaxle in reverse using the control lever and select lever.
3) Install the special tool (09432-21101) onto the input shaft.
4) Screw a bolt 10 mm (0.39 inch) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
5) Remove the lock nut while using the bolt as a spinner handle stopper.
7. Remove the fifth speed synchronizer sleeve and fifth speed shift fork.
8. Remove the fifth speed synchronizer hub, synchronizer ring, 5th speed gear and needle bearing.
9. Remove the intermediate gear using the special tool (09455-21000).
10. Remove the reverse idler gear shaft bolt and restriction ball assembly.
11. Remove the transaxle case fixing bolts in the clutch housing and then remove the transaxle case.
12. Remove the differential oil seal and oil guide.
13. Remove the output shaft bearing outer race and spacer using the special tool (09455-32200).
14. Remove the intermediate shaft bearing outer race and spacer.
15. Remove the differential bearing outer race and spacer.
16. Remove the reverse shift lever and the reverse shift shoe.
17. Remove the reverse gear shaft and reverse gear.
18. Remove the spring pins using the special tool (09414-11000).
19. Disassembly of the shift rail and fork assembly.
1) Shift the first-second gear shift fork into the second gear.
2) Shift the third-fourth gear shift fork into the fourth gear.
3) Remove the first-second gear shift rail and fork assembly with select lever pushed to fifth-reverse gear shift rail.
4) Remove the shift rail and fork assembly of the third-fourth/ fifth-reverse gear with the select lever pushed to first-second gear shift rail.
20. Remove the bearing retainer.
21. Lift up the input shaft assembly and remove the intermediate shaft assembly.
22. Remove the output shaft assembly and differential gear assembly.
23. Remove the intermediate shaft bearing outer race and spacer and oil guide using the special tool (09455-32200).
24. Remove the output shaft bearing outer race and spacer using the special tool (09455-32200).
25. Remove the differential bearing oil seal.
26. Remove the input shaft oil seal.
Reassembly
1. Install the drive shaft oil seal using the special tool (09431-21200).
2. Install the input shaft front oil seal using the special tool (09431-21000).
3. Install the differential gear bearing outer race and spacer using the special tools (09500-11000, 09532-11500).
4. Install the output shaft bearing outer race and spacer using the special tool (09500-11000, 09532-11500).
5. Install the oil guide and intermediate shaft bearing outer race and spacer using the special tools (09500-21000, 09432-33400)
6. Install the differential gear assembly and output shaft assembly.
7. While raising the input shaft assembly, install it simultaneously with the intermediate shaft assembly.
8. Install the retainer.
9. Reassembly of shift rail assembly.
1) Set the first-second speed shift sleeve at second speed.
2) Set the third-fourth speed shift sleeve at fourth speed.
3) Install the first-second shift rail and fork assembly with the select lever pulled to fifth-reverse shift rail side.
4) Install the third-fourth/fifth-reverse shift rail and fork assembly together with the select lever fully pushed to first-second rail side.
5) Install the third-fourth/reverse shift rail and fork assembly with the select lever fully pushed to first-second rail side.
6) Turn the shift rail to engine shift lug.
10. Reassembly of spring pin.
1) Install the spring pins using the special tool (09414-11100).
2) When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
3) Do not reuse the spring pins.
11. Install the reverse gear lever assembly.
12. Install the reverse gear shaft and reverse gear in the direction illustrated.
13. Install the reverse shift lever and shoe.
14. Install the input shaft bearing outer race and spacer to the transaxle case using the special tools (09500-21000, 09432-33400)
15. Install the intermediate shaft bearing outer race and spacer to the transaxle case using the special tools (O9500-21000, 09432-33400)
16. Install the output shaft bearing outer race and spacer to the transaxle case using the special tools (09500-11000, 0953211500).
17. Install the differential bearing outer race and spacer to the transaxle case using the special tools (09500-11000, 09532-11500).
18. Install the drive shaft oil seal to the transaxle case using the special tool (09431-21200).
19. Reassembly of spacers (adjustment of end play).
1) Place two pieces of solder measuring about 10 mm (0.4 inch) in length and 3 mm (0.12 inch) in diameter on the bearing outer race as shown in the illustration, and install the outer race.
2) Install the transaxle case and tighten the bolts to the specified torque.
3) Remove the transaxle case.
4) Remove the outer races and remove the solder.
5) Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play.
Standard Value: mm (inch)
Input shaft front bearing end play: 0.01T - 0.12L (0.0004T - 0.0047L)
Input shaft rear bearing end play: 0.01T - 0.12L (0.0004T - 0.0047L)
Intermediate shaft front bearing end play: 0.01T - 0.12L (0.0004T - 0.0047L)
Intermediate shaft rear bearing end play: 0.01T - 0.12L (0.0004T - 0.0047L)
Output shaft rear bearing end play: 0.01T - 0.12L (0.0004T - 0.0047L)
Differential case end play: 0.01T - 0.12L (0.0004T - 0.0047L)
20. Install the oil guide to the transaxle case.
21. Apply specified sealant to the clutch housing side of the transaxle case.
Specified sealant: THREE BOND 1216
22. Install the transaxle case to the clutch housing assembly and tighten the (13) bolts.
23. Install the restriction ball and gasket.
24. Center the shaft with a Phillips screwdriver.
25. Tighten the reverse idler gear shaft bolt to the specified torque.
26. Install the poppet balls, poppet springs and poppet plugs.
27. Install the backup lamp assembly.
28. Install the intermediate gear using the special tool (09432-33300)
29. Install the fifth speed gear and needle roller bearing synchronizer ring and synchronizer hub.
30. Install the fifth speed shift fork and the 5th speed synchronizer sleeve at the same time.
31. Install the spring pin using the special tool (09414-11100).
32. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
CAUTION: Do not reuse the spring pin.
33. Reassembly of lock nuts.
1) Install the special tool (09432-21101)onto the input shaft.
2) Screw a bolt [10 mm (0.39 inch)] into the hole on the surface of clutch housing and attach a spinner handle to the special tool (09432-21101).
3) Shift the transaxle in reverse using control lever and select lever.
4) Tighten the lock nut to the specified torque.
5) Stake the lock nut.
34. Apply the specified sealant to the rear cover and install the rear cover.
Specified sealant: THREE BOND 1216
35. Install the backup light switch, gasket and mounting bracket.
36. Install the speedometer driven gear assembly.