Part 1
DISASSEMBLY/ASSEMBLY5TH GEAR PREINSPECTION
5TH GEAR THRUST CLEARANCE
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.100 - 0.220 mm (0.0039 - 0.0087 inch)
Maximum: 0.270 mm (0.0106 inch)
2. If the clearance exceeds the maximum, inspect the contact surfaces of the 5th gear and the clutch hub. Replace worn or damaged parts.
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY/ASSEMBLY
1. Preinspect the thrust clearance of 5th gear before disassembly. (Refer to 5th Gear Preinspection.)
2. Disassemble in the order indicated in the table.
3. Adjust the bearing preload.
4. Assemble in the reverse order of disassembly.
LOCKNUT (PRIMARY SHAFT), LOCKNUT (SECONDARY SHAFT) DISASSEMBLY NOTE
1. Mount the transaxle on the SST
2. Lock the primary shaft by using, the SST.
3. Shift to 1st 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 COMPONENT DISASSEMBLY NOTE
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 control rod from the clutch housing.
4. Separate the shift rod and shift fork component from each of the clutch hub sleeves.
PRIMARY SHAFT GEAR COMPONENT, SECONDARY SHAFT GEAR COMPONENT ASSEMBLY NOTE
- Install the primary and secondary shaft gear components together.
SHIFT FORK AND SHIFT ROD COMPONENT ASSEMBLY NOTE
1. Shift to 2nd gear and position the shift fork and shift rod component as shown.
2. Insert the spring seat and spring into the reverse lever shaft. 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 so that the ball goes into the shaft. This will line up the rod 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 three grooves in the control end).
5. Pull up on the ball part of the control end so that the steel ball goes into the detent in the groove.
CRANK LEVER COMPONENT, CRANK LEVER SHAFT ASSEMBLY NOTE
1. Install a new 0-ring to the crank lever shaft.
2. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
3. Align the pin holes of the crank lever shaft and the clutch housing, and insert a new pin.
5TH/REVERSE SHIFT ROD END, 5TH/REVERSE SHIFT ROD ASSEMBLY NOTE
1. Install the shift rod A into the shift rod end B.
2. Align the mark on the shift rod with the mounting bolt hole in the shift rod end as shown in the figure, and tighten the gate mounting bolt.
Tightening torque: 11.8 - 13.7 Nm (120 - 140 kgf-cm, 105 - 121 inch lbs.)
REVERSE IDLER GEAR, REVERSE IDLER SHAFT ASSEMBLY NOTE
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 (arrow), and at the same time, face the reverse idler shaft screw hole in the direction shown in the figure.
TRANSAXLE CASE COMPONENT ASSEMBLY NOTE
1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to the specified torque.
Tightening torque 38 - 51 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft. lbs.)
2. Insert the SSTs through the drive shaft and joint shaft hole.
5TH/REVERSE CLUTCH HUB COMPONENT, 5TH/REVERSE SHIFT FORK ASSEMBLY NOTE
- Install the 5th/reverse clutch hub component and the 5th/reverse shift fork together.
LOCKNUT (PRIMARY SHAFT), LOCKNUT (SECONDARY SHAFT) ASSEMBLY NOTE
1. Shift to 1st gear.
2. Lock the primary shaft by using the SST
3. Tighten new locknuts onto the primary and secondary shafts.
Tightening torque 128 - 196 Nm (13 - 20 kgf-m, 95 - 144 ft. lbs.)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.100 - 0.220 mm (0.0039 - 0.0087 inch)
6. If not as specified, reassemble the transaxle.
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY/ASSEMBLY
NOTE
- The oil seals do not need to be removed unless you are replacing them.
1. Disassemble in the order indicated in the table.
2. Adjust the bearing preload.
3. Assemble in the reverse order of disassembly.
OIL SEAL (PRIMARY SHAFT) DISASSEMBLY NOTE
CAUTION
- Do not damage the clutch housing.
- Remove the oil seal from the clutch housing by using a screwdriver.
BEARING RACE (SECONDARY SHAFT) DISASSEMBLY NOTE
- Remove the bearing race by lifting it and the funnel out together.
ROLL PIN DISASSEMBLY NOTE
- Align the groove for removal of the clutch housing pin with the position of the roll pin, then tap the pin out by using a pin punch.
OIL SEAL (CHANGE ROD) DISASSEMBLY NOTE
- Remove the oil seal by using a screwdriver.
OIL SEAL (DIFFERENTIAL) DISASSEMBLY NOTE
- Remove the oil seal by using a screwdriver.
REVERSE LEVER SHAFT DISASSEMBLY NOTE
1. Remove the roll pin by using pliers.
2. Protect the reverse lever shaft with a rag and use pliers to remove the shaft.
BEARING RACE (TRANSAXLE CASE) DISASSEMBLY NOTE
- Remove the bearing race by using the SST
BEARING RACE (DIFFERENTIAL) DISASSEMBLY NOTE
1. Install the SST onto the differential bearing race, and support the SST so that it does not fall.
2. Remove the bearing race by using the SST.
BEARING RACE (DIFFERENTIAL), ADJUSTMENT SHIM (DIFFERENTIAL) ASSEMBLY NOTE
1. Assemble the adjustment shim to the differential case.
2. Apply transaxle oil to the bearing race, and assemble it to the differential case by using a suitable pipe.
BEARING RACE (TRANSAXLE CASE), ADJUSTMENT SHIM (TRANSAXLE CASE) ASSEMBLY NOTE
1. Assemble the adjustment shim to the primary and secondary shaft bearing seats in the transaxle case.
2. Apply transaxle oil to each bearing race, and assemble them to the transaxle case by using a suitable pipe.
OIL SEAL (DIFFERENTIAL) ASSEMBLY NOTE
1. Using the SST and a hammer, tap the new oil seal in evenly until the SST contacts the transaxle case.
2. Apply transaxle oil to the lip of the oil seal.
OIL SEAL (CHANGE ROD) ASSEMBLY NOTE
1. Assemble the new oil seal by using a suitable pipe.
2. Apply transaxle oil to the lip of the oil seal.
Outer diameter of pipe: 26.0 mm (1.02 inch)
OIL SEAL (PRIMARY SHAFT) ASSEMBLY NOTE
- Apply transaxle oil to the outer circumference of the oil seal, and assemble it to the transaxle case by using a suitable pipe.
PRIMARY SHAFT COMPONENT PREINSPECTION 3RD GEAR THRUST CLEARANCE
1. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05 - 0.29 mm (0.002 - 0.011 inch)
Maximum: 0.34 mm (0.013 inch)
2. If the clearance exceeds the maximum, inspect the contact surfaces of the 3rd gear, 2nd gear and 3rd/4th clutch hub. Replace worn and damaged parts.
4TH GEAR THRUST CLEARANCE
1. Measure the clearance between the 4th gear and the bearing.
Clearance: 0.17 - 0.37 mm (0.007 - 0.015 inch)
Maximum: 0.42 mm (0.017 inch)
2. If the clearance exceeds the maximum, inspect the contact surfaces of the 4th gear, bearing, and 3rd/4th clutch hub. Replace worn and damaged parts.
PRIMARY SHAFT COMPONENT DISASSEMBLY/ASSEMBLY
1. Preinspect the thrust clearance of 3rd gear and 4th gear before disassembly. (Refer to Primary Shaft Component Preinspection.)
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of disassembly.
BEARING (4TH GEAR END) DISASSEMBLY NOTE
1. Support the primary shaft to keep it from falling.
2. Disassemble the bearing by using the SSTs.
3RD/4TH CLUTCH HUB COMPONENT, 3RD SYNCHRONIZER RING, 3RD GEAR DISASSEMBLY NOTE
1. Support the primary shaft to keep it from falling.
2. Disassemble the 3rd/4th clutch hub component, 3rd synchronizer ring, and 3rd gear by using the SST
BEARING (PRIMARY SHAFT END) DISASSEMBLY NOTE
- Disassemble the bearing by using the SST
BEARING (PRIMARY SHAFT END) ASSEMBLY NOTE
- Assemble the new bearing by using the SSTs.
3RD GEAR, 3RD SYNCHRONIZER RING, 3RD/4TH CLUTCH HUB COMPONENT ASSEMBLY NOTE
- Assemble the 3rd gear, 3rd synchronizer ring, and 3rd/4th clutch hub component by using a press.
4TH SYNCHRONIZER RING, 4TH GEAR, BEARING (4TH GEAR END) ASSEMBLY NOTE
1. Assemble the 4th synchronizer ring, 4th gear, and a new bearing by using the SSTs.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05 - 0.29 mm (0.002-0.011 inch)
3. Measure the clearance between the 4th gear and bearing.
Clearance: 0.17 - 0.37 mm (0.007 - 0.015 inch)
4. If not as specified, reassemble the primary shaft component.