Disassembly
STEP1
Disassemble in the numbered order shown in the image.
Transaxle
Position the transaxle hanger (49 G030 440) on the engine stand (49 0107 680A), and mount the transaxle on the hanger.
Lock Nut
Lock the primary shaft using the primary shaft holder (49 G030 440), and remove the lock nut.
NOTE:
a. Turn the transaxle on its side.
b. Shift to 1st or 2nd.
Shift Fork (5th)
Remove the shift fork (5th) together with the clutch hub assembly.
Primary Gear
Remove the primary gear using two flat-tipped screwdrivers to pry it off the secondary shaft.
CAUTION: Use a cloth to protect the transaxle case at the points where the screwdrivers contact it.
Crankshaft Lever Shaft
The crankshaft lever shaft can be removed by moving the change rod in the direction shown in the image while turning the shaft with a flat-tipped screwdriver.
Shift Fork and Shift Rod Assembly
The shift fork and shift rod assembly can be removed as follows:
1. After aligning the ends of the interlock sleeve and of the control lever, 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 shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each clutch hub sleeves.
STEP2
Disassemble in the numbered order shown in the image.
Bearing Outer Race (on the engine side of the primary shaft)
After mounting the bearing remover (49 FT01 361), reverse the clutch housing, and use a piece of pipe to tap out the bearing outer race through the primary shaft hole.
WARNING: Before the bearing outer race comes all the way out, tap with lighter strokes and hold it to prevent it from falling.
Bearing Outer Race (between secondary shaft and engine)
Remove the bearing outer race by lifting out the funnel and the race together.
Spring Pin
After aligning the groove for removal of the clutch housing pin with the position of the spring pin, tap the pin out using a pin punch.
Bearing Outer Race (differential side)
After mounting the bearing remover (49 FT01 361), use a piece of pipe to tap out the bearing outer race through the driveshaft hole.
WARNING: Before the bearing outer race comes all the way out, tap with lighter strokes and hold it to prevent it from falling.
STEP 3
Disassemble in the numbered order shown in the image.
NOTE: Replace the bearing inner race with a new one.
Bearing Outer Race and 4th Gear
Remove the bearing outer race together with 4th gear by mounting the pulley boss puller (49 0636 145) on 4th gear.
WARNING: Hold the shaft with one hand so that it doesn't fall.
3rd Gear
Remove 3rd gear together with 2nd gear by mounting the remover plate (49 G030 370) on 2nd gear as shown.
CAUTION: The clutch hub sleeve must be meshed with 1st gear.
WARNING: Hold the shaft with one hand so that it doesn't fall.
Clutch Hub Assembly (1st and 2nd gears)
Remove the 1st and 2nd clutch hub assembly by holding 1st gear. Remove it with the gears intact.
WARNING: Hold the shaft with one hand so that it doesn't fall.
Bearing Inner Race (drive gear side)
Remove the bearing inner race from the shaft using the plate (49 F401 366A) and attachment H (49 B092 374) in the bearing remover set (49 G017 1A0).
WARNING: Hold the shaft with one hand so that it doesn't fall.
Bearing Inner Race (4th gear side of primary shaft gear)
Remove the bearing inner race from the shaft using the plate (49 F401 366A) and attachment G (49 B092 373) in the bearing remover set (49 G017 1A0).
WARNING: Hold the shaft with one hand so that it doesn't fall.
Clutch Hub Assembly (3rd and 4th gears)
Set the pulley boss puller (49 0636 145) onto the 3rd gear, and remove the clutch hub assembly together with the gear.
WARNING: Hold the shaft with one hand so that it doesn't fall.
Differential
Disassemble the differential in the numbered order shown in the image.
CAUTION: Replace the bearing inner race with a new one.
Side gear
Remove the side gear from the gear case turning it backward on top of the pinion gear.
Spring pin
With the gear case secured in a vice, use a pin punch to tap out the spring pin.
Side bearing inner race (side opposite the ring gear)
Remove the bearing inner race from the gear case using the plate (49 F401 366A) and attachment J (49 B092 375) in the bearing remover set (49 G017 1A0).
WARNING: Hold the gear case with one hand so that it doesn't fall.
Side bearing inner race (ring gear side)
Remove the side bearing inner race using a combination of parts from the bearing puller set (49 0839 425C).