Disassembly
Precaution1. Clean the transaxle exterior thoroughly with steam or cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. (Except sealed bearings.) 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.
Step 1
1. Rear cover
2. Locknut
3. Locknut
4. Primary reverse synchronizer gear
5. Secondary reverse synchronizer gear
6. Roll pin
7. Shift fork
8. Clutch hub assembly
9. Synchronizer ring
10. Primary 5th gear
11. Gear sleeve
12. Secondary 5th gear
13. Lock bolt
14. Guide bolt
15. Lock bolt, and ball and spring
16. Transaxle case assembly
17. Magnet
18. Reverse idler shaft
19. Reverse idler gear
20. Lock bolt
21. Shift rod (5th/Rev.) and clip
22. Shift rod end (5th/Rev.)
23. Pin
24. Crank lever shaft
25. O-ring
26. Crank lever assembly
27. Shift fork and shift rod assembly
28. Steel ball
29. Spring
30. Primary shaft gear assembly
31. Secondary shaft gear assembly
32. Differential assembly
33. Clutch housing
34. Synchronizer key spring
35. Clutch hub sleeve
36. Synchronizer key
37. Clutch hub
1. Measure the thrust clearance between 5th gear and transaxle case referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly NOTE.
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.10-0.22 mm (0.0039-0.0087 in)
Maximum: 0.27 mm (0.0106 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.
4. Remove the locknut.
Transaxle Case assembly
1. Remove the lock bolt (1), the guide bolt (2).
2. Remove the lock bolt, spring and ball (3).
3. Remove the transaxle case installation bolts, and remove the transaxle case.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control lever, then turn the shift rod counter clockwise.
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.
Step 2
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly Note
Bearing outer race (clutch housing)
NOTE: If it is difficult to remove the bearing outer race, remove it with the SST.
Remove the bearing outer race with the SST
Bearing outer races (transaxle case)
NOTE: If it is difficult to remove the bearing outer races, remove it with the SST.
Remove the bearing outer races with the SST.
Roll pin
Align the groove for removal of the clutch housing pin with the position of the roll pin, then tap the pin out using a pin punch.
Bearing outer race (differential)
Remove the bearing outer race with the SST.
On-vehicle replacement
Oil seals
Jack up the vehicle, support it on safety stands, and then drain the transaxle oil. Next, use the following procedure to replace the driveshaft oil seals:
1. Remove the front wheel(s).
2. Remove the splash shield(s).
3. Separate the front stabilizer from the lower arm.
4. Remove the clinch bolt and pull the lower arm downward. Separate the knuckle from the lower arm ball-joint.
NOTE: Be careful not to damage the ball-joint dust boot.
5. Remove the cotter pin then disconnect the tie-rod end with the SST.
CAUTION
- Do not damage the oil seal.
- Do not separate the driveshaft by pulling the disc plate.
6. Separate the left driveshaft from the transaxle by prying with a bar inserted between the shaft and the case.
7. Remove the oil seal with a flat-tipped screwdriver.
8. Tap the new oil seal into the transaxle case with the SST.
NOTE
- Tap in until the oil seal installer contacts the case.
- Coat the oil seal lip with transaxle oil.
9. Replace the driveshaft end clip with a new one. Insert the clip with the gap at the top of the groove.
10. Install the driveshaft as follows:
1. Pull the front hub outward, then fit the driveshaft into the transaxle.
2. Insert the driveshaft into the transaxle by pushing on the wheel hub assembly.
NOTE
- Be careful not to damage the oil seal.
- After installation is finished, pull the front hub slowly outward to check that the driveshaft is held securely by the clip.
11. Install the lower arm ball-joint to the knuckle, and tighten the clinch bolt.
Tightening torque: 43-54 N.m (4.4-5.5 m-kg, 32-40 ft-lb)
12. Install the tie-rod end and new cotter pin.
Tightening torque: 29-44 N.m (3.0-4.5 m-kg, 22-33 ft-lb)
13. Adjust and tighten the stabilizer.
Tightening torque: 16-23 N.m (1.6-2.3 m-kg, 12-17 ft-lb)
Dimension: 20.1 ± 2 mm (0.79 ± 0.08 in)
14. Install the drain plug.
Tightening torque: 39-59 N.m (4.0-6.0 m-kg, 29-43 ft-lb)
15. Install the wheel.
Tightening torque: 88-118 N.m (9.0-12.0 m-kg, 65-87 ft-lb)
16. Add the correct quantity of the specified oil.
Type:
All-season ATF: DEXRON-II
Above -18 °C (0 °F):
API: GL-4 or GL-5
SAE 80W-90 or SAE 90
Capacity: 3.35 liters (3.5 US qt, 2.9 imp qt)
Step 3
1. Shift fork (3rd/4th)
2. Interlock sleeve
3. Roll pin
4. Control end
5. Shift fork (1st/2nd)
6. Roll pin
7. Control lever
8. Control rod
9. Bearing inner race
10. Secondary 4th gear
11. Retaining ring
12. Secondary 3rd gear
13. Secondary 2nd gear
14. Synchronizer ring
15. Retaining ring
16. Clutch hub assembly
17. Synchronizer key spring
18. Synchronizer key
19. Clutch hub
20. Clutch hub sleeve (reverse gear)
21. Synchronizer ring
22. Secondary 1st gear
23. Bearing inner race
24. Secondary shaft Inspection
25. Bearing inner race
26. Primary 4th gear
27. Synchronizer ring
28. Retaining ring
29. Clutch hub assembly (3rd/4th)
30. Synchronizer key spring
31. Synchronizer key
32. Clutch hub
33. Clutch hub sleeve
34. Synchronizer ring
35. Primary 3rd gear
36. Bearing inner race
37. Primary shaft
1. Disassemble in the order shown in the image, referring to Disassembly NOTE.
Disassembly note
Bearing inner race (secondary 4th gear end)
Remove the bearing inner race and secondary 4th gear with the SST.
CAUTION: Hold the shaft with one hand so that it does not fail.
Secondary 3rd gear and 2nd gear
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear with the SST.
CAUTION: Hold the shaft with one hand so that it does not fail.
Clutch hub assembly and Secondary 1st gear
1. Remove the retaining ring.
2. Remove the clutch hub assembly (reverse gear) and 1st gear as shown in the image.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing inner race (secondary shaft end)
Remove the bearing inner race with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing inner race (primary 4th gear end)
Remove the bearing inner race with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Clutch hub assembly (3rd/4th)
1. Remove the retaining ring.
2. Remove the clutch hub assembly with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing inner race (primary shaft end)
Remove the bearing inner race with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Step 4 (Differential)
1. Inspect side gears and pinion gears for backlash.
CAUTION: Do not remove inner races if not necessary.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Side bearing inner race (side opposite ring gear)
Remove the race from the gear case with the SST.
CAUTION: Hold the gear case with one hand so that It does not fall.
Side bearing Inner race (ring gear side)
Remove the race with a combination of parts from the SST.