Disassembly
Precaution1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. 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 a compressed air, and check that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
5th/Reverse Gear and Housing Parts
1. Measure the thrust clearance between 5th gear and the transaxle case, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
1. Rear cover
2. Locknut (Primary shaft)
3. Stop plate
4. Locknut (Secondary shaft)
5. 5th shift fork
6. Clutch hub assembly (5th)
7. Synchronizer ring (5th)
8. 5th gear
9. Gear sleeve
10. Secondary 5th gear
11. Lock bolt and washer
12. Back-up light switch
13. Neutral switch
14. Transaxle case assembly
15. Magnet
16. Reverse idler shaft
17. Reverse idler gear
18. 5th shift rod
19. 5th shift rod end
20. Pin
21. Crank lever shaft
22. Crank lever assembly
23. Shift fork and shift rod assembly
24. Steel ball
25. Spring
26. Primary shaft gear assembly
27. Secondary shaft gear assembly
28. Differential assembly
29. Clutch housing
30. Synchronizer spring
31. Clutch hub sleeve
32. Synchronizer key
33. Clutch hub
34. 3rd/4th shift fork
35. Interlock sleeve
36. Control lever
37. 1st/2nd shift fork
38. Control rod
39. Control end
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06 - 0.26 mm (0.0024 - 0.0102 in.)
Maximum: 0.31 mm (0.0122 in.)
2. If the clearance exceeds the 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 SST.
2. Lock the primary shaft with the SST.
3. Shift to 1st or 2nd gear to lock the rotation of the primary shaft.
CAUTION: Do not reuse the removed locknut.
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 shift 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
CAUTION: Do not remove an oil seal if not necessary.
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Blind plug
1. Remove the roll pin with pliers.
Reverse lever shaft
1. Protect the reverse lever shaft with a rag and remove the shaft with pliers.
Oil seal (Change rod)
1. Remove the oil seal with a screwdriver.
Funnel and bearing outer race (Secondary shaft)
NOTE: Remove the bearing outer race with a screwdriver if necessary.
1. Insert a screwdriver between the clutch housing and bearing outer race.
2. Pry the bearing outer race free.
1. Remove the bearing outer race by lifting out the funnel and race together.
Oil seal (Primary shaft)
CAUTION: Do not damage the clutch housing.
1. Remove the oil seal with a screwdriver.
Oil seal (Differential)
1. Remove the oil seal with a screwdriver.
Bearing outer race (Differential)
1. Install the SST to the bearing outer race.
2. Remove the bearing outer race with a suitable pipe.
Bearing outer race and adjust shim (Differential)
1. Install the SST to the bearing outer race.
2. Remove the bearing outer race and adjust shim.
Oil seal (Speedometer gear case)
1. Remove the oil seal as shown in the image.
Oil seal
Replacement (On-vehicle)
Jack up the vehicle and support it with safety stands. Drain the transaxle oil. Next, use the following procedure to replace the driveshaft oil seal:
1. Remove the front wheel.
2. Remove the splash shield.
3. Separate the front stabilizer from the lower arm.
CAUTION: Do not damage the dust boots.
4. Remove the clinch bolt and pull the lower arm downward. Separate the knuckle from the lower arm ball joint.
5. Loosen the nut and disconnect the tie-rod end with the SST.
CAUTION: Do not subject the tripod joint to shock when removing the driveshaft.
6. Disconnect the driveshaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle.
7. Suspend the driveshaft with a rope.
8. Remove the oil seal with a screwdriver.
NOTE:
- Tap in until the oil seal installer contacts the case.
- Coat the oil seal lip with transaxle oil.
9. Tap the new oil seal into the transaxle case with the SST.
10. Replace the driveshaft end clip with a new one. Insert the driveshaft with the end-gap of the clip facing upward.
Primary Shaft Assembly
1. Measure the thrust clearances 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: 0.06 - 0.21 mm (0.002 - 0.008 in.)
Maximum: 0.26 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 or damaged parts.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball bearing.
Clearance: 0.21 - 0.61 mm (0.008 - 0.024 in.)
Maximum: 0.66 mm (0.026 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 or damaged parts.
Disassembly note
Bearing and 4th gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the ball bearing and 4th gear with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd) and 3rd gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the clutch hub assembly (3rd/4th), synchronizer ring (3rd) and 3rd gear with the SST.
Bearing
1. Remove the bearing with the SST.
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear, 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 clutch hub assembly (1st/2nd). Replace worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary 3rd gear.
Clearance: 0.18 - 0.51 mm (0.007 - 0.020 in.)
Maximum: 0.56 mm (0.022 in.)
2. If the clearance exceeds the maximum, check the contact surfaces of the 2nd gear, secondary 3rd gear, and clutch hub assembly (1st/2nd). Replace worn or damaged parts.
Disassembly note
Bearing inner race and secondary 4th gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with the SST.
Secondary 3rd gear and 2nd gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the retaining ring.
2. Remove the secondary 3rd gear and 2nd gear with the SST.
Clutch hub assembly (1st/2nd), synchronizer ring (1st) and 1st gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the clutch hub assembly (1st/2nd), synchronizer ring (1st) and 1st gear with the SST.
Bearing inner race (Secondary shaft end)
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race with the SST.