Disassembly

DISASSEMBLY
PRECAUTION
- Clean the transaxle exterior thoroughly with a steam cleaner or clear or cleaning solvent before disassembly.
- Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
- Clean out all holes and passages with compressed air, and verify that there are no obstructions.





1. Remove release fork assembly and bearing.





2. Remove clutch release fork boot.





3. Remove shift control lever assembly.





4. Remove transmission shift control housing.





5. Remove back up lamp switch.





6. Using the pin punch, remove shift rail roll pin.

NOTE: Do not use old roll pin again.





7. With a magnet, remove springs and ball after loosing interlock puppet plate bolts.





8. Loose a reverse idle shaft bolt on the transmission case housing side.





9. Remove retainer after loosing the front retainer bolt.





10. Remove snap ring.





11. Remove front bearing.





12. Remove transmission case housing after loosing case housing bolt.





13. Remove bearing retainer bolt.

NOTE: In case of 4WD, remove bearing retainer bolt after loosing the transfer case bolt.





14. Remove reverse idle shaft after loosing a reverse idle shaft bolt on the adapter side.





15. Using the pin punch, remove 3th shift fork pin.

NOTE: Do not use old roll pin again.





16. Remove 3rd shift rail after setting each gear to the neutral position.





17. In order to disassemble main shaft assembly, counter shaft assembly and shift rail from adapter, heat double bearing installed part of adapter with electrical heater (Leister 4000) or SST (09432-3E000) as shown.

NOTE:
a. Secure main shaft assembly, counter shaft assembly and shift rail with a strap or cord for ease of removal, and then hang them on the jack or suitable crane. Because it is dangerous to pick up them with hands.
b. Heat the double bearing installed part of adapter at 400°C for about 4 min.
c. In case of removing by force with press or hammer instead of electrical heater, it is possible to damage double bearing.





18. Disassemble it tapping adapter with rubber hammer lightly after heating.