Disassembly

DISASSEMBLY

Transaxle Case





1. Remove back-up lamp switch, PNP switch, drain plug, and filler plug from transaxle case.





2. Remove snap ring from reverse idler shaft as shown.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.





5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end as shown.
b. Pull out the attached bolt (M6), and remove reverse idler gear shaft from case.





6. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.
7. Remove mainshaft rear bearing snap ring from case.





8. Remove check plugs, springs, and check balls from case.





9. Remove transaxle case mounting bolts.





10. Remove input shaft rear bearing adjusting shim from transaxle case
11. Remove oil gutter from transaxle case.





12. Remove differential side bearing outer race and adjusting shim from transaxle case using Tool.





13. Remove differential oil seal from transaxle case using Tool.





14. Remove Welch plugs from transaxle case using Tool.

Clutch Housing
1. Remove transaxle case from clutch housing.





2. Remove check plugs, check springs, check pins, and check balls from housing.





3. Remove 3rd & 4th bracket retaining pin using Tool.





4. Remove 3rd & 4th shift fork stopper ring.
5. Remove 3rd & 4th fork rod.
6. Remove 3rd & 4th shift fork and bracket.





7. Remove interlock plunger and check ball.
8. Remove 5th & reverse bracket stopper ring.





9. Remove retaining pins from 5th & reverse shift fork and 5th & reverse bracket using Tool.
10. Remove 5th & reverse fork rod.
11. Remove interlock pin from 5th & reverse fork rod using Tool.
12. Remove reverse switch bracket and 5th & reverse bracket.





13. Remove check ball from housing.
14. Remove retaining pin for 1st & 2nd shift fork and 1st & 2nd bracket using Tool.
15. Remove 1st & 2nd fork rod.
16. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.





17. Remove both input shaft and mainshaft assemblies from housing.





18. Remove final drive assembly from housing.
19. Remove oil pocket from housing.





20. Remove mainshaft bearing retainer from housing.
21. Cut off oil channel using a cutter as shown.





22. Remove mainshaft front bearing from housing using Tool.





23. Using a magnet or other suitable tool, remove selector pin from selector shaft.





24. Remove selector shaft and plug, then remove selector using Tool.





25. Remove reamer bolts, then remove select check leaf spring, return spring, steel ball, reverse gate, selector arm, bearing, and bushing.

CAUTION: Be careful not to lose the steel ball.





26. Remove retaining pin and plug from striking lever using Tool.
27. Remove striking rod, then striking lever from housing.





28. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing.

CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.





29. Remove differential oil seal from housing using Tool.





30. Remove differential side outer race from housing using Tool.