Disassembly

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 the 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 the oil gutter and 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 Welch plug.





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





14. 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.

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





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





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





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





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





28. Remove gear components from clutch housing in the following procedure.
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.





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





32. Remove differential side bearing outer race (clutch housing side).





33. Remove input shaft oil seal.

CAUTION: Be careful not to damage clutch housing.