Disassembly Procedure

Clutch Housing and Transaxle Case Components Disassembly

Disassembly Procedure





1. Assemble the SST.





2. Lift the transaxle and mount it on the SST.
3. Remove the drain plug and the oil level plug.
4. Remove the neutral switch and back-up light switch.
5. Remove the reverse idler shaft retaining bolt.
6. Remove the straight pin.





7. Remove the shift push pin and select push pin.
8. Remove the select lever set and shift component.








9. Remove the sealing cap, detent spring seat, detent spring and detent ball as shown in the figure.





10. Remove the sealing caps.

Note: The cast hexagon inner diameter of the plug is 27mm (1.063 in).

11. Remove the transaxle case fixing bolts.

Front side fixing bolts





Rear side fixing bolts








12. Stretch the snap ring of the primary shaft rear bearing and secondary shaft (No.1) rear bearing at the sealing cap hole, and remove the transaxle case.

Note: If the transaxle case is not removed, pull the primary shaft from the clutch housing side.





13. Remove the snap rings.
14. Remove the oil pass.





15. Remove the control rod bearings from the transaxle case using the SST.





16. Remove the shift lever shaft bearing from the transaxle case using the SST.





17. Remove the secondary shaft (No.2) rear bearing outer race and bearing adjust shim from the transaxle case, using the SST.





18. Remove the differential oil seal from the transaxle case using a flathead screwdriver.





19. Remove the differential side bearing outer race and adjust shim from the transaxle case using the SST.
20. Remove the magnet from the clutch housing.





21. Remove the baffle plate.





22. Remove the 5th/6th shift fork retaining bolt and reverse shift fork retaining bolt.
23. Remove the reverse control rod.
24. Remove the 5th/6th control rod.
25. Remove the reverse shift fork and 5th/6th shift fork.
26. Remove the 3rd/4th shift fork spring pin using a pin punch.





27. Remove the 1st/2nd shift fork retaining bolt.
28. Remove the 1st/2nd control rod.





29. Remove the 3rd/4th control rod end (A and B) spring pin using a pin punch.
30. Remove the 3rd/4th control rod (B), 3rd/4th control rod end (B), and 3rd/4th shift fork.





31. Remove the snap ring using a flathead screwdriver, and remove the counter lever pivot.





32. Remove the 3rd/4th control rod (A).
33. Remove the 1st/2nd shift fork.
34. Remove the counter lever.





35. Remove each gear component.
1) Remove the reverse idler gear component.
2) Remove the secondary shaft (No.2) component.
3) Remove the primary shaft component and secondary shaft (No.1) component at the same time.
4) Remove the differential component.

Caution: The oil funnel in the clutch housing can be damaged when removing the secondary shafts component.





36. Remove the primary shaft bearing cover and secondary shaft (No.1) bearing cover from the clutch housing.





37. Pry and remove the roller guide for the secondary shaft (No.1) front bearing using a flathead screwdriver as shown in the figure.





38. Remove the secondary shaft (No.1) front bearing using the SST.
39. Remove the oil funnel of the secondary shaft (No.1).





40. Remove the primary shaft front bearing using the SST.





41. Remove the primary shaft oil seal using a flathead screwdriver.





42. Remove the secondary shaft (No.2) front bearing outer race using the SST.
43. Remove the oil funnel of the secondary shaft (No.2).





44. Remove the differential side bearing outer race from the clutch housing using the SST.

Note: Wrap the SST with tape so that the SST tabs hook onto the bearing outer race as shown in the figure.





45. Remove the differential oil seal from the clutch housing using a flathead screwdriver.





46. Remove the control rod bearings, from the clutch housing.