RS5F51A

DISASSEMBLY





1. Remove drain plug and filler plug.
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control assembly.





4. Remove check plugs (3 pieces), check springs (3 pieces), check balls (3 pieces) and shift check sleeve (1 piece).





5. Remove transaxle case fixing bolts.
6. Remove bore plug.

CAUTION: Be careful not to damage transaxle case.

7. While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case.
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and input shaft rear bearing adjusting shim from transaxle case.





10. Remove differential side bearing outer race (transaxle case side) and then adjust shim.





11. Remove differential oil seal.
12. Remove magnet from clutch housing.





13. With shift lever in 5th position, remove bracket bolts from reverse lever assembly. Lift reverse lever assembly to remove.

CAUTION: Be careful not to lose shifter cap.

14. Pull out reverse fork rod then remove reverse shift fork.





15. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of 5th shift fork using pin punch.





16. Remove stopper rings for 5th & reverse bracket.
17. Pull out 5th & reverse fork rod and remove 5th shift fork and 5th & reverse bracket.
18. Remove check balls (2 pieces) and inter lock pin.





19. Remove retaining pin of 3rd & 4th bracket using pin punch.
20. Remove stopper rings for 3rd & 4th shift fork.
21. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and bracket.
22. Remove shift check sleeve from clutch housing.





23. Remove retaining pin of 1st & 2nd shift fork using pin punch.
24. Pull out 1st & 2nd with bracket.
25. Remove 1st & 2nd shift fork.
26. Remove retaining pin of 1st & 2nd bracket using pin punch and separate 1st & 2nd fork rod and bracket.





27. Remove gear components from clutch housing.
a. While tapping input shaft with plastic hammer, remove input shaft assembly, mainshaft assembly and reverse idler gear assembly as a set.

CAUTION: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.

b. Remove final drive assembly.





28. Remove bearing retainer and then the mainshaft front bearing.
29. Remove oil channel on mainshaft side.
30. Remove differential oil seal.
31. Remove differential side bearing outer race (clutch housing side).





32. Remove input shaft oil seal.

CAUTION: Be careful not to damage clutch housing.

REASSEMBLY





1. Using a drift, install input shaft oil seal.

CAUTION: Oil seals are not reusable. Never reuse them.





2. Using a drift, install differential oil seal.

CAUTION: Oil seals are not reusable. Never reuse them.





3. Install oil channel on mainshaft side.

CAUTION: Be careful with orientation of installation.





4. Using a drift, install mainshaft front bearing.





5. Install bearing retainer.





6. Install differential side bearing outer race.





7. Install final drive assembly into clutch housing.





8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.

CAUTION: Be sure not to damage input shaft oil seal.





9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then install retaining pin.

CAUTION: Retaining pins are not reusable. Never reuse them.





10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install retaining pin.

CAUTION: Retaining pins are not reusable. Never reuse them.

11. Install shift check sleeve.





12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with interlock pin.
13. Install stopper ring onto 3rd-4th shift fork.

CAUTION: Stopper rings are not reusable. Never reuse them.

14. Install retaining pin onto 3rd-4th bracket.

CAUTION: Retaining pins are not reusable. Never reuse them.

15. Install 2 check balls.





16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork rod.
17. Install stopper ring onto 5th-reverse bracket.

CAUTION: Stopper rings are not reusable. Never reuse them.





18. Install retaining pin onto 5th shift fork.

CAUTION: Retaining pins are not reusable. Never reuse them.

19. Install reverse shift fork and reverse fork rod.
20. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.

CAUTION: Do not drop shifter cap.





b. While lifting reverse shift fork, align cam with 5th-reverse bracket.





c. Tighten mounting bolts to specified torque, and then install reverse lever assembly.
21. Install the magnet onto clutch housing.
22. Install selected input shaft adjusting shim onto input shaft.
23. Install baffle plate and oil gutter.
24. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.

CAUTION: Do not reuse the snap ring.





c. Apply sealant to mating surfaces of transaxle case and clutch housing. Use Genuine Anaerobic Liquid Gasket or equivalent.

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

d. With snap ring of mainshaft rear bearing temporarily installed, place transaxle case over clutch housing.
e. Install control assembly.

CAUTION: Do not reuse the O-ring.

f. Install shift check and stopper bolt.

CAUTION: Shift check and stopper bolt are not reusable. Never reuse them.





g. Through bore plug mounting hole, with snap ring stretched, move shift lever of control assembly to 2nd speed, and lift up mainshaft assembly.
h. Securely install snap ring onto mainshaft rear bearing.





i. Tighten mounting bolts.
Bolt A: 50.0 - 53.9 Nm (5.1 - 5.4 kgf-m, 37 - 39 ft. lbs.)
Bolt B: 63.0 - 66.9 Nm (6.5 - 6.8 kgf-m, 47 - 49 ft. lbs.)

CAUTION: Always replace bolts B as they are self-sealing bolts.





25. Using a drift, install bore plug.

CAUTION: Bore plugs are not reusable. Never reuse them.





26. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3 check ball plugs.

CAUTION: Check ball plugs are not reusable. Never reuse them.





27. Apply sealant to threads of neutral switch and reverse lamp switch, then install them into transaxle case. Use Genuine Anaerobic Liquid Gasket or equivalent.

28. Install gaskets onto drain plug and filler plug, and then install them into transaxle case.

CAUTION:
- Gaskets are not reusable. Never reuse them.
- After oil is filled, tighten filler plug to specified torque.