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 verify that there are no obstructions.
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.
Preinspection
5th gear thrust clearance
1. Measure the clearance between the 5th gear and the transaxle case by using 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 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 they are being replaced.
Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Bearing race (secondary shaft)
Remove the bearing race by lifting it and the funnel out together.
Roll pin
Align the pin removal groove and the roll pin, then tap the pin out by using a pin punch.
Bearing race (differential)
Remove the bearing race by using the SST and a press.
Bearing race (transaxle case)
Remove the bearing race by using the SST.
Replacement (on-vehicle)
Oil seal (differential)
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 driveshaft 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 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 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.
Primary Shaft Assembly and Secondary Shaft Assembly
1. 3rd/4th shift fork
2. Interlock sleeve
3. Roll pin
4. Control end
5. 1st/2nd shift fork
6. Roll pin
7. Control lever
8. Control rod
9. Bearing
10. Secondary 4th gear
11. Retaining ring
12. Secondary 3rd gear
13. 2nd gear
14. 2nd synchronizer ring
15. Retaining ring
16. 1st/2nd clutch hub assembly
17. 1st synchronizer ring
18. 1st gear
19. Bearing (secondary shaft end)
20. Secondary shaft gear
21. Bearing (4th gear end)
22. 4th gear
23. 4th synchronizer ring
24. Retaining ring
25. 3rd/4th clutch hub assembly
26. 3rd synchronizer ring
27. 3rd gear
28. Bearing (primary shaft end)
29. Primary shaft
30. Synchronizer springs
31. Synchronizer key
32. Clutch hub
33. Reverse gear clutch hub sleeve
34. Synchronizer springs
35. Synchronizer key
36. Clutch hub
37. Clutch hub sleeve
1. Measure the thrust clearance of all gears before disassembly, referring to Pre-inspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
Preinspection
Thrust clearance
1. Measure the clearance between the 2nd gear and secondary 3rd gear.
Clearance: 0.175 - 0.455 mm (0.0069 - 0.0179 in)
Maximum: 0.505 mm (0.0199 in)
2. Measure the clearance between the 1st gear and differential drive gear.
Clearance: 0.05 - 0.28 mm (0.002 - 0.011 in)
Maximum: 0.33 mm (0.0130 in)
3. Measure the clearance between the 4th gear and the bearing inner race.
Clearance: 0.165 - 0.365 mm (0.0065 - 0.0144 in)
Maximum: 0.415 mm (0.0163 in)
4. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05 - 0.20 mm (0.002 - 0.008 in)
Maximum: 0.25 mm (0.010 in)
Disassembly note
Bearing 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. Shift the gears to 1st gear.
3. 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 with a press.
Bearing (secondary shaft end)
1. Support the secondary shaft to keep it from falling.
2. Remove the bearing by using the SST.
Bearing (4th gear end)
Remove the bearing 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 (primary shaft end)
Remove the bearing by using the SST.