Manual Transaxle-Wagon
DISASSEMBLY-STEP 1
Disassemble in the numbered order shown in the image.
Transaxle
Position the transaxle hanger (49 B017 0A0) on the engine stand (49 0107 680A), and mount the transaxle on the hanger.
NOTE Transaxle hanger (49 G030 495) which is used for the previous model can be used for all new models except the B6 engine.
Lock Nut
Lock the primary shaft with the primary shaft holder (49 F401 440), and remove the lock nut.
NOTE: Shift to 1st or 2nd.
Shift Fork (5th)
Remove the shift fork (5th) together with the clutch hub assembly.
Shift rod (5th and reverse)
1. Insert a pin punch or suitable rod into the spring pin hole of the shift rod.
2. Pull out the shift rod while turning the pin punch or the rod (5 speed).
Reverse Shift Rod
To remove the reverse shift rod, wrap it with a cloth and turn it with pliers while pulling out.
Gate
Remove the gate by lifting it out together with the reverse lever.
NOTE: Before removing the gate, place the transaxle in neutral.
Spring Pin
The spring pin used for attaching the control rod and control end can easily be removed by the following procedure:
1. Make sure the transaxle is in neutral and the interlock sleeve and control lever are in the position as shown in the image.
2. Move the change rod to turn the control rod counter clockwise.
3. Hold the change rod in the turned position and push inward on it to raise the control rod upward.
4. Remove the spring pin with a pin punch.
Primary Shaft Gear Assembly, Secondary Shaft Gear Assembly and Shift Fork Assembly
Lift the primary shaft, secondary shaft and shift fork assemblies out as a unit.
Control End
Pull the change rod rearward and remove the control end and ball and spring.
CAUTION: Be careful not to lose the ball and spring.
Crank Lever Shaft
Turn the lever with a screw driver while pushing the lever out of the housing, and remove.
DISASSEMBLY-STEP 2
Disassemble in the numbered order shown in the image.
Bearing Outer Race (secondary shaft gear)
Remove the bearing outer race by lifting the funnel and the race out together
Spring pin
For removing the selector attaching pin, match the pin's position with the removing groove, then tap the pin out with a pin punch and hammer.
Bearing Outer Race (differential, clutch housing and transaxle case)
Remove the bearing outer races with the bearing remover (49 FT01 361) and hammer. Do not remove the oil seals, unless replacement is necessary due to damage.
Bearing Outer Race (5th gear, transaxle case)
Remove both of the bearing outer races with a brass rod positioned on the race by means of the grooves in the case.
NOTE: Remove the races gradually and evenly.
Bearing Outer Race (4th gear, transaxle case)
Remove the bearing outer races gradually with the boot air out tool (49 0208 701A) or a screwdriver with a bent end.
Oil Seal (differential)
Check the oil seals and if necessary replace them.
Use a pipe of the proper size to tap the seal out.
NOTE: Remove the oil seal gradually and evenly.
DISASSEMBLY-STEP 3
Disassemble in the numbered order shown in the image.
Shift Fork Assembly
Disassemble the 1st - 2nd shift fork, interlock sleeve and 3rd - 4th shift fork after setting them as shown in the image. Slide the 3rd - 4th shift fork and interlock sleeve off the shaft.
Bearing Inner Race (1st gear end of primary shaft gear)
Press the bearing inner race from the shaft with the plate (49 F401 366A) from the bearing remover set (49 B017 1A0) and attachment (49 B092 368) and a press.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing Inner Race (4th gear end of primary shaft gear)
Press the bearing inner race from the shaft with the plate (49 F401 366A) from the bearing remover set (49 B017 1A0) and attachment (49 B092 367) and a press.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing Inner Race and 4th Gear (secondary shaft gear assembly)
Remove the bearing inner race and the 4th gear with the rear axle shaft bearing puller (49 0187 520). Position the puller between the two sets of gear teeth on the 4th gear.
CAUTION: Hold the shaft with one hand so that it does not fall.
Clutch Hub Assembly (3rd - 4th gear)
Set the pulley boss puller (49 0636 145) onto the 3rd gear, between the two sets of teeth, and then, by using a press, remove the clutch hub assembly together with the gear.
CAUTION: Hold the shaft with one hand so that it does not fall.
Clutch Hub Assembly (1st - 2nd gear)
Support the 1st gear and press it and the clutch hub assembly off the secondary shaft.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing Inner Race (drive pinion end of secondary shaft gear)
Remove the bearing inner race from the shaft with the plate (49 F401 366A) from the bearing remover set (49 B017 1A0) and attachment (49 B092 369) and press against the shaft with a proper rod.
CAUTION: Hold the shaft with one hand so that it does not fall.
DIFFERENTIAL
Disassemble the differential in the numbered order shown in the image.
Backlash
Before disassembly, check the backlash of side gears and pinion gears.
Standard backlash: 0-0.1 mm (0-0.004 in)
Knock-pin
To remove the knock-pin from the pinion shaft, place the gear case on a vise and knock the pin out with a 4 mm diameter rod, and hammer.
NOTE: Insert the rod into the knock-pin hole from the ring gear mounting surface side.
Side Bearing Inner Race (side opposite the ring gear)
Remove the bearing inner race from the gear case by using the plate (49 F401 366A) from the bearing remover set (49 B017 1A0) and attachment (49 B092 371).
CAUTION: Hold the gear case with one hand so that it does not fall.
Side Bearing Inner Race (ring gear side)
Remove the side bearing inner race by using a combination of parts from the bearing puller set (49 0839 425C).