Disassembly Procedure
Disassembly Procedure1. Remove the drain plug and the filler cap.
2. Remove the neutral switch and reverse switch.
3. Remove the shift check bolt and stopper bolt.
4. Remove the shift control component.
5. Remove the check plugs, check springs, check balls, and shift check sleeve as shown in the figure.
6. Remove the transaxle case installation bolt.
7. Remove the bore plug using screwdriver.
8. Stretch the snap ring of the secondary shaft rear bearing at the bore plug hole, and remove the transaxle case.
9. Remove the baffle plate and the oil pass.
10. Remove the snap ring, secondary shaft adjust shim, primary shaft rear bearing adjust shim from the transaxle case.
11. Remove the differential side bearing outer race (transaxle case side) using the SST, and remove the adjust shim.
12. Remove the welt plug using a fit stick.
13. Remove the differential oil seal (transaxle case side) using a screwdriver.
14. Remove the magnet from clutch housing.
15. Shift to 5th gear.
16. Remove the reverse lever component bracket bolt.
17. Lift the reverse lever component, and remove it.
18. Remove the reverse fork rod.
19. Remove the reverse shift fork.
20. Shift 3rd/4th fork rod to the 3rd gear, and remove the retaining pin of 5th shift fork using a pin punch.
21. Remove the C-ring of the 5th/reverse bracket.
22. Remove the 5th/reverse fork rod, and remove the 5th shift fork and 5th/reverse bracket.
23. Remove the check balls and the interlock pin from the clutch housing.
24. Remove the retaining pin of 3rd/4th fork rod bracket using a pin punch.
25. Remove the two C-rings of the 3rd/4th shift fork.
26. Remove the 3rd/4th fork rod, and remove the 3rd/4th shift fork and 3rd/4th bracket.
27. Remove the shift check sleeve from the clutch housing.
28. Remove the retaining pin of 1st/2nd shift fork using a pin punch.
29. Remove the 1st/2nd fork rod and 1st/2nd bracket at a time.
30. Remove the 1st/2nd shift fork.
31. Remove the retaining pin of the 1st/2nd bracket using a pin punch, and remove the 1st/2nd bracket from the 1st/2nd fork rod.
32. Remove each gear component.
1) Tap the primary shaft using a plastic hammer.
Caution: The oil channel in the clutch housing can be damaged when removing the secondary shaft component. Remove the secondary shaft component to right above.
2) Remove the primary shaft component, secondary shaft component, and reverse idler gear component at the same time.
3) Remove the differential.
33. Remove the secondary shaft bearing retainer.
Warning: Using a heat gun will cause the clutch housing to heat up greatly. To prevent burns wear gloves whenever using a heat gun.
Caution: The clutch housing will be damaged if heated above 120°C (248°F). Heat the clutch housing below 120°C (248°F).
Note: If the secondary shaft front bearing cannot be removed easily, heat the clutch housing to about 100°C (212°F) using a heat gun and remove it.
34. Remove the secondary shaft front bearing using a screwdriver.
35. Remove the oil channel of the secondary shaft.
36. Remove the differential oil seal (clutch housing side) using a screwdriver.
Warning: Using a heat gun will cause the clutch housing to heat up greatly. To prevent burns wear gloves whenever using a heat gun.
Caution: The clutch housing will be damaged if heated above 120°C (248°F). Heat the clutch housing below 120°C (248°F).
Note: If the differential side bearing outer race can't be removed easily, heat the clutch housing to about 100°C (212°F) using a heat gun and remove it.
37. Remove the differential side bearing outer race using the SST.
38. Remove the primary shaft oil seal using a screwdriver.