Disassembly
Precaution1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
3. Clean out all holes and passages with compressed air, and check that there are no obstructions.
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. 5th clutch hub assembly Inspection
7. 5th synchronizer ring Inspection
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 springs
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 5th gear thrust clearance, referring to Preinspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
Preinspection
5th gear thrust clearance
1. Measure the clearance between the 5th gear and the transaxle case by using 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 the 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly note
Locknut
1. Mount the transaxle on the SSTs.
2. Lock the primary shaft by using the SST.
3. Shift to 1st or 2nd gear to lock the rotation of the primary shaft.
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. 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
NOTE: The oil seals do not need to be removed unless you are replacing them.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Oil seal (differential)
Remove the oil seal.
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.
Oil seal (primary shaft)
CAUTION: The clutch housing is made of aluminum, and is therefore easily dented and scratched by metal tools. When removing the oil seal, keep contact with the clutch housing to a minimum.
Remove the oil seal from the clutch housing as shown in the image.
Funnel and bearing race (secondary shaft)
Remove the bearing race by lifting it and the tunnel out together.
Bearing race (differential)
Remove the bearing race by using the SST.
Bearing race and adjustment shim (differential)
1. Install the SST to the bearing race.
2. Remove the bearing race and adjustment shim.
Oil seal (speedometer gear case)
Remove the oil seal as shown in the image.
Oil seal
Replacement (on-vehicle)
On level ground, jack up the vehicle and support it evenly on safety stands. Drain the transaxle oil. Next, use the following procedure to replace the drive shaft oil seal:
1. Remove the front wheel.
2. Remove the splash shield.
3. Separate the front stabilizer from the lower arm.
CAUTION: The sharp edges of the SST can slice the tie rod end dust boot. Install the SST so that the sharp edges are between the dust boot and the knuckle.
4. Remove the clinch bolt and pull the lower arm downward. Separate the knuckle from the lower arm ball joint.
5. Loosen the nut until it is flush with the end of the ball stud.
6. Disconnect the tie rod end from the knuckle by using the SST.
7. Disconnect the drive shaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle.
8. Suspend the drive shaft with a rope.
9. Remove the oil seal.
10. Using the SST and a hammer, tap the new oil seal in evenly until the SST contacts the transaxle case.
11. Coat the lip of the oil seal with transaxle oil.
12. Replace the drive shaft end clip with a new one. Insert the drive shaft with the end-gap of the clip facing upward.
13. Tighten the stabilizer nut until the specified amount of thread is exposed at the end of the bolt.
Dimension A: 17 - 19 mm (0.67 - 0.75 in)
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 the 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 3rd/4th clutch hub. Replace worn or damaged parts.
4th gear thrust clearance
1. Measure the clearance between the 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, bearing, and 3rd/4th clutch hub. Replace worn or damaged parts.
Disassembly note
Bearing and 4th gear
1. Support the primary shaft to keep it from falling.
2. Remove the bearing and 4th gear by using the SST.
3rd/4th clutch hub assembly, 3rd synchronizer ring, and 3rd gear
1. Support the primary shaft to keep it from falling.
2. Remove the 3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear by using the SST.
Bearing
Remove the bearing by using the SST,
Secondary Shaft Assembly
1. Measure the thrust clearance at 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 the 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 1st/2nd clutch hub assembly. Replace worn or damaged parts.
2nd gear thrust clearance
1. Measure the clearance between the 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 1st/2nd clutch hub assembly. Replace worn or damaged parts.
Disassembly note
Bearing (secondary shaft) and secondary 4th gear
1. Support the secondary shaft to keep it from falling.
2. Remove the bearing and secondary 4th gear by using the SST.
Secondary 3rd gear and 2nd gear
1. Support the secondary shaft to keep it from falling.
2. Remove the secondary 3rd gear and 2nd gear by using the SST.
1st/2nd clutch hub assembly, 1st synchronizer ring, and 1st gear
1. Support the secondary shaft to keep it from falling.
2. Remove the 1st/2nd clutch hub assembly, 1st synchronizer ring and 1st gear.
Bearing (secondary shaft end)
1. Support the secondary shaft to keep it from falling.
2. Remove the bearing by using the SST.