Disassembly
DISASSEMBLY1. Remove the drain plug and filler plug.
2. Remove the park/neutral position switch and back-up lamp switch.
3. After removing the shift check and stopper bolt, remove the control assembly.
4. Remove the 2 check ball plugs, 2 check springs, and 2 check balls as shown. Discard the check ball plug.
CAUTION: Check ball plugs are not reusable.
5. Remove the transaxle case bolts as shown.
6. Remove the bore plug.
CAUTION: Be careful not to damage transaxle case.
7. While spreading the snap ring of the mainshaft rear bearing located at bore plug hole, remove the transaxle case.
8. Remove the oil gutter and baffle plate.
9. Remove the snap ring, mainshaft rear bearing adjusting shim, and input shaft rear bearing adjusting shim from the transaxle case.
10. Remove the differential side bearing outer race (transaxle case side) using Tool as shown, and then remove the adjusting shim.
11. Remove the welch plug with a suitable punch and hammer as shown.
12. Remove the differential oil seal with a suitable tool as shown.
13. Remove the magnet from the clutch housing.
14. Remove the reverse check ball plug, reverse check spring, reverse shift check sleeve, and check ball. Discard the check ball plug.
CAUTION:
^ Do not reuse the check ball plug.
^ Do not drop the check ball.
15. With the shift lever in 5th position, remove the bracket bolts from the reverse lever assembly as shown. Lift the reverse lever assembly to remove.
CAUTION: Retain the shifter cap for installation.
16. Pull out the reverse fork rod then remove the reverse shift fork.
17. Remove the retaining pin of the reverse bracket.
18. Pull out the reverse lever and the reverse bracket fork rod.
19. Remove the two check balls and the interlock pin.
20. Shift the 3rd-4th fork rod to the 3rd position. Remove the retaining pin of the 5th-6th shift fork using a pin punch.
21. Remove the stopper rings for the 5th-6th bracket.
22. Pull out the 5th-6th fork rod and remove the 5th-6th shift fork and the 5th-6th bracket.
23. Remove the check balls (2 pieces) and interlock pin.
24. Remove the retaining pin of 3rd-4th bracket using pin punch.
25. Remove the stopper rings for 3rd-4th shift fork.
26. Pull out the 3rd-4th fork rod and remove 3rd-4th shift fork and bracket.
27. Remove the shift check sleeve from the clutch housing.
28. Remove the retaining pin of 1st-2nd shift fork using a suitable pin punch.
29. Pull out the 1st-2nd fork rod with bracket.
30. Remove the 1st-2nd shift fork.
31. Remove the retaining pin of 1st-2nd bracket using a suitable pin punch and separate the fork rod and bracket.
32. Remove the gear components from the clutch housing.
a. While tapping the input shaft with a plastic hammer, remove the input shaft assembly, mainshaft assembly, and reverse idler gear assembly as a set.
CAUTION: Always withdraw the mainshaft straight out. Failure to do so can damage the resin oil channel on the clutch housing side.
b. Remove the final drive assembly.
33. Remove the bearing retainer and then the mainshaft front bearing as shown.
34. Remove the oil channel on the mainshaft side.
35. Remove the differential oil seal (clutch housing side) using Tool as shown.
36. Remove the differential side bearing outer race (clutch housing side) using Tool as shown.
37. Remove the input shaft oil seal using a suitable tool as shown.
CAUTION: Do not damage the clutch housing sealing surface.