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. 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. Guide bolt
15. Transaxle case assembly
16. Magnet
17. Reverse idler shaft
18. Reverse idler gear
19. 5th shift rod
20. 5th shift rod end
21. Pin
22. Crank lever shaft
23. Crank lever assembly
24. Shift fork and shift rod assembly
25. Steel ball
26. Spring
27. Primary shaft gear assembly
28. Secondary shaft gear assembly
29. Differential assembly
30. Clutch housing
31. Synchronizer spring
32. Clutch hub sleeve
33. Synchronizer key
34. Clutch hub
35. 3rd/4th shift fork
36. Interlock sleeve
37. Control lever
38. 1st/2nd shift fork
39. Control rod
40. Control end
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.
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 by using 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 oil seals unless necessary.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Blind plug
Remove the roll pin with pliers.
Reverse lever shaft
Protect the reverse lever shaft with a rag and remove the shaft with pliers.
Oil seal (Change rod)
Remove the oil seal with a screwdriver.
Funnel and bearing race (Secondary shaft)
NOTE:
- Remove the bearing race with a screwdriver if necessary.
1. Insert a screwdriver between the clutch housing and bearing race.
2. Pry the bearing race free.
Remove the bearing race by lifting out the funnel and race together.
Oil seal (Primary shaft)
CAUTION: Do not damage the clutch housing.
Remove the oil seal with a screwdriver.
Oil seal (Differential)
Remove the oil seal with a screwdriver.
Bearing race (Differential)
Remove the bearing race by using the SST.
Bearing race and adjust shim (Differential)
1. Install the SST to the bearing race.
2. Remove the bearing race and adjust shim.
Oil seal (Speedometer gear case)
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 by using 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 by using transaxle oil.
9. Tap the new oil seal into the transaxle case by using 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. It 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.
Remove the ball bearing and 4th gear by using 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 by using the SST.
Bearing
Remove the bearing by using 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 (secondary shaft) and secondary 4th gear
CAUTION: Hold the shaft with one hand so that it does not fall.
Remove the bearing and secondary 4th gear by using 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 by using 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.
Remove the clutch hub assembly (1st/2nd), synchronizer ring (1st) and 1st gear by using the SST.
Bearing (Secondary shaft end)
CAUTION: Hold the shaft with one hand so that it does not fall.
Remove the bearing by using the SST.