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 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 5th gear thrust clearance, 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
12. Back-up light switch
13. Guide bolt
14. Neutral switch
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 control 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 key 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
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance by using a dial indicator.
Clearance: 0.15-0.26mm (0.006-0.010 in)
Maximum: 0.31 mm (0.012 in)
2. If the clearance exceeds 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 gear to lock the rotation of the primary shaft.
CAUTION: Do not reuse the removed locknuts.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary shafts.
Shift fork and control rod assembly
1. Align the ends of the interlock sleeve and of the control lever (arrow). Turn the control rod counterclockwise.
2. While holding the 1st/2nd control 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 control rod from the clutch housing.
4. Separate the control rod and shift fork assembly from each of the clutch hub sleeves.
Clutch Housing and Transaxle Case Components
CAUTION: Do not remove the oil seal if not necessary.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Oil seal (differential)
Remove the oil seal by using a screwdriver.
Reverse lever shaft
1. Remove the roll pin.
2. Protect the reverse lever shaft with a rag and remove the shaft.
Oil seal (change rod assembly)
Remove the oil seal.
Oil seal (primary shaft)
CAUTION: Do not damage the clutch housing.
Remove the oil seal by using a screwdriver.
Bearing race (secondary shaft)
Remove the bearing race by lifting it and the funnel out together.
Bearing race (differential)
1. Install the SST to the bearing race.
2. Remove the bearing race by using a press.
Bearing race and adjustment shim (differential)
1. Install the SST to the bearing race.
2. Press out the bearing race and remove the adjustment shim.
Oil seal (speedometer gear case)
Remove the oil seal as shown in the image.
Primary Shaft Assembly
1. Measure the thrust clearance 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: 0.26mm (0.010 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 3rd gear, 2nd gear and clutch hub. Replace worn and damaged parts.
4th gear thrust clearance
1. Measure the clearance between 4th gear and the ball bearing.
Clearance: 0.14-0.39mm (0.00-0.015 in)
Maximum: 0.44mm (0.017 in)
2. If the clearance exceeds the maximum, check the contact surfaces of the 4th gear, ball bearing, and clutch hub. Replace worn and 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
1. Remove the retaining ring.
CAUTION: Hold the shaft with one hand so that it does not fall.
2. Remove the clutch hub assembly (3rd/4th), synchronizer ring (3rd), and 3rd gear by using the SST.
Bearing
NOTE: Use protective plates in the jaws of the vise.
Remove the bearing by using the SST.
Secondary Shaft Assembly
1. Measure the thrust clearance of 1st gear and 2nd gear before disassembly, 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: 0.05-0.28mm (0.002-0.011 in)
Maximum: 0.33mm (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 and damaged parts.
2nd gear thrust clearance
1. Measure the clearance between 2nd gear and secondary 3rd gear.
Clearance: 0.18-0.51mm (0.007-0.020 in)
Maximum: 0.56mm (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 and 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
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
CAUTION: Hold the shaft with one hand so that it does not fall.
3. 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 a press.
Bearing (secondary shaft end)
CAUTION: Hold the shaft with one hand so that it does not fall.
Remove the bearing by using the SSTs.