Gear: Service and Repair
PREINSPECTION
5th gear thrust clearance:
1. Measure the 5th gear thrust clearance with a dial indicator. Clearance should be within 0.08 - 0.15 mm (0.0032 - 0.0059 inch)
2. 1f the clearance exceeds 0.20 mm (0.0079 inch), check the contact surfaces of the 5th gear and the clutch hub. Replace worn or damaged parts.
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY / ASSEMBLY
1. Disassemble in the order shown in the illustration, referring to Preinspection and Disassembly Note.
2. Assemble in the reverse order of disassembly. referring to Assembly Note.
Disassembly Note
Locknut (2, 6)
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 (26)
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.
Inspection
Synchronizer Ring (5, 9)
1. Inspect individual synchronizer ring teeth for damage, wear, and cracks.
2. Inspect tapered surface for wear or cracks.
NOTE: Set the synchronizer ring squarely in the gear; then measure around the circumference.
3. Measure the clearance between the synchronizer ring and flank surface of the gear. Standard clearance should be within 1.12 - 1.88 mm (0.044 - 0.074 inch) and a minimum of 0.8 mm (0.031 inch).
Clutch Hub Assembly (8)
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer key for damage, wear, and cracks.
4. Measure the clearance between the hub sleeve and the shift fork.
5th Gear (10)
1. Measure the clearance between the shaft gears and the gears.
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
Reverse Idler Gear (20)
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever. Standard clearance should be within 0.10 - 0.32 mm (0.004 - 0.013 inch) and a maximum of 0.37 mm (0.015 inch).
Assembly Note
Primary Shaft Gear Assembly And Secondary Shaft Gear Assembly (29, 30)
Install the primary shaft gear assembly and the secondary shaft gear assembly together.
Shift Fork And Shift Rod Assembly (26)
1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft; then install the steel ball, and place a scraper so that it contacts the steel ball.
3. With the edge of the control end against the scraper, push the control end in the direction of the arrow in the illustration so that the ball goes into the shaft. The rod will line up with the shift rod coupling hole in the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove of the 3 grooves in the control end.
5. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.
Crank Lever Assembly And Crank Lever Shaft (25, 24)
NOTE: Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.
5th/Reverse Shift Rod End And 5th/Reverse Shift Rod (22, 21)
NOTE: The marks (indicated by the arrows) and the shift rod end mounting bolt hole must face the same direction.
Install the shift rod end (1) and the shift rod (2), and tighten the gate mounting bolt.
Reverse Idler Gear And Reverse Idler Shaft (20, 19)
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever (indicated by the arrow), and, at the same time, face the reverse idler shaft screw hole in the direction shown in the illustration.
Transaxle Case Assembly (17)
Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case; then tighten the transaxle case installation bolts to 19 - 25 Nm (14 - 18 ft. lbs.).
5th/Reverse Clutch Hub Assembly And 5th/Reverse Shift Fork (8, 7)
Install the 5th/reverse clutch hub assembly and the 5th/reverse shift fork together.
Locknut (6, 2)
1. Shift to 1st gear.
2. Lock the primary shaft by using the SST.
3. Tighten new locknuts on the primary and secondary shafts to 128 - 205 Nm (95 - 151 ft. lbs.).
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator. Clearance should be within 0.06 - 0.26 mm (0.0024 - 0.0102 inch) and a maximum of 0.31 mm (0.0122 inch).
6. If not as specified, reassemble the transaxle.