Disassembly And Assembly

TRANSAXLE ASSEMBLY


Disassembly and Assembly


COMPONENTS

Case and Housing Components











Gear Components































Shift Control Components











Final Drive Components











DISASSEMBLY
1. Remove drain plug and gasket from clutch housing, using a suitable tool and then drain gear oil.
2. Remove filler plug and gasket from transaxle case.





3. Remove selector lever (1) retaining pin with a pin punch to remove selector lever.
4. Remove bracket (2) and position switch (3) from transaxle case.










5. Remove transaxle case bolts ( ).










6. Remove reverse idler shaft bolt ( ) and seal washer.





7. Remove transaxle case (2) while rotating shifter lever A (1) in the direction as shown.





8. Remove selector spring (1) from return bushing (A).





9. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
10. Remove selector (4) from clutch housing.





11. Remove reverse idler shaft assembly (1) according to the following procedures.
a. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).

NOTE:
It is easier to pull up when shifting each fork rod to each shaft side.
b. Remove reverse idler shaft assembly and reverse fork rod (6) from clutch housing.
12. Remove spring washer from clutch housing.





13. Pull up and remove input shaft assembly (1), mainshaft assembly (2), fork rod (3), and 1st-2nd fork rod (4) from clutch housing.

NOTE:
It is easier to pull up when shifting each fork rod to each shaft side.





14. Remove final drive assembly (1) from clutch housing.
15. Remove magnet from clutch housing.





16. Remove differential side oil seals (1) from clutch housing and transaxle case.

CAUTION:
Never damage clutch housing and transaxle case.





17. Remove differential side bearing outer race (1) from clutch housing, using a brass rod.

CAUTION:
Never damage clutch housing.





18. Remove differential side bearing outer race (1) from transaxle case, using a brass rod.

CAUTION:
Never damage transaxle case.
19. Remove shim (2) from transaxle case.





20. Remove shifter lever A (1) retaining pin, using a suitable tool.
21. Remove shifter lever A from transaxle case.





22. Remove shifter lever B (1) from transaxle case.





23. Remove oil gutter (1) from transaxle case.





24. Remove bushings (1) from transaxle case, using a suitable tool.





25. Remove mainshaft rear bearing outer race from transaxle case, using a suitable tool.
26. Remove mainshaft rear bearing adjusting shim from transaxle case.





27. Remove snap ring (1) and oil channel (2) from transaxle case.





28. Remove input shaft oil seal (1) from clutch housing, using a suitable tool.

CAUTION:
Never damage clutch housing.





29. Remove mainshaft front bearing outer race (1) from clutch housing, using Tool (A) and a suitable tool (B).

Tool number : KV381054S0 (J-34286)

30. Remove oil channel (2) from clutch housing.





31. Remove bushing (1) from clutch housing, using suitable tool.





32. Remove two way connector (1) from clutch housing.
33. Remove plug from clutch housing. (With ABS models)
34. Remove vehicle speed sensor from clutch housing. (Without
ABS models)





35. Remove pinion gear (1) and pinion shaft (2) from clutch housing.

ASSEMBLY





1. Install pinion gear (1) and pinion shaft (2) to clutch housing.

CAUTION:
Replace transaxle assembly when replacing clutch housing.
2. Install plug to clutch housing. (With ABS models)
3. Install vehicle speed sensor to clutch housing. (Without ABS models)

NOTE:
Apply specified transaxle fluid to O-rings prior to installation. Maintenance.





4. Install two way connector (1) to clutch housing.





5. Install bushings (1) so that they becomes even to clutch housing edge surface, using a suitable tool (A).
6. Install oil channel to clutch housing.

CAUTION:
Never reuse oil channel.





7. Install mainshaft front bearing outer race to clutch housing, using Tool (A).

Tool number : KV38100200 ( - )


CAUTION:
Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.





8. Install input shaft oil seal (1) to clutch housing, using Tool (A).

Tool number : ST33220000 ( - )






9. Install snap ring (1) and oil channel (2) to transaxle case.

CAUTION:
- Select and install snap ring that has the same thickness as previous one.
- Replace transaxle assembly when replacing transaxle case.
10. Install mainshaft rear bearing adjusting shim to transaxle case.

CAUTION:
Select mainshaft rear bearing adjusting shim according to the following procedures when replacing mainshaft adjusting shim, 6th main gear, 5th main gear, or 4th main gear.
- Replace mainshaft adjusting shim.
- If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim.
- If new mainshaft adjusting shim is thicker than previous one, offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim.
- Replace 6th main gear, 5th main gear, or 4th main gear.
- Measure the thickness of the main gear used before and the new main gear
- Increase the thickness of the mainshaft rear bearing adjusting shim, if the difference is smaller than 0.025 mm (0.0010 in).
- Decrease the thickness of the mainshaft rear bearing adjusting shim, if the difference is greater than 0.025 mm (0.0010 in).





11. Install mainshaft rear bearing outer race to transaxle case, using
Tool (A).

Tool number : KV38100200 ( - )


CAUTION:
Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.





12. Install bushings (1) to transaxle case, using suitable (A).





13. Install oil gutter (1) to transaxle case.





14. Install shifter lever B (1) to transaxle case.

CAUTION:
Replace shifter lever A and shifter lever B as a set.
15. Install shifter lever A to transaxle case.

CAUTION:
Replace shifter lever A and shifter lever B as a set.





16. Install retaining pin to shifter lever A (1), using a pin punch.

CAUTION:
Never reuse retaining pin.
17. Install shim to transaxle case.





18. Install differential side bearing outer race (transaxle case side) to transaxle case, using Tool (A).

Tool number : ST33400001 (J-26082)


CAUTION:
Replace differential side bearing outer race (transaxle case side) and differential side bearing inner race (transaxle case side) as a set.





19. Install differential side bearing outer race (clutch housing side) to clutch housing, using Tool (A).

Tool number : KV38100200 ( - )


CAUTION:
Replace differential side bearing outer race (clutch housing side) and differential side bearing inner race (clutch housing side) as a set.





20. Install differential side oil seals (1) to clutch housing and transaxle case, using Tool.

Tool number : KV325 QAA (B.vi 1666-B)

A : Transaxle case side
B : Clutch housing side







21. Install magnet to clutch housing.
22. Install final drive assembly to clutch housing.





23. Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.





24. Install mainshaft assembly (1) according to the following procedures.
a. Pull up input shaft assembly (2) and fork rod (3).
b. Set 1st-2nd fork rod (4) to mainshaft assembly, and then install them to clutch housing.





25. Install reverse idler shaft assembly (1) according to the following procedures.
a. Install spring washer to clutch housing.
b. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).

NOTE:
It is easier to pull up when shifting each fork rod to each shaft side.
c. Set reverse fork rod (6) to reverse idler shaft assembly, and then install them to clutch housing.





26. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
27. Install selector (4) to clutch housing.

CAUTION:
Replace selector lever and selector as a set.





28. Install selector spring (1) to return bushing (A).
29. Apply recommended sealant to transaxle case mounting surface.
- Use Genuine Liquid Gasket, Three Bond 1215 or an equivalent.

CAUTION:
- Never allow old liquid gasket, moisture, oil, or foreign matter to remain on mounting surface.
- Check that mounting surface is not damaged.
- Apply liquid gasket bead continuously.





30. Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown.










31. Install reverse idler shaft bolt (Black Arrow) according to the following procedures.
a. Install seal washer to reverse idler shaft mounting bolt, and install reverse idler shaft bolt to transaxle case.

CAUTION:
Never reuse seal washer.
b. Tighten reverse idler shaft bolt to the specified torque. Disassembly And Assembly.










32. Tighten transaxle case bolts (Black Arrow) to the specified torque. Disassembly And Assembly.





33. Install position switch (1) according to the following procedures.
a. Apply recommended sealant to position switch thread.
- Use Genuine Liquid Gasket, Three Bond 1215 or an equivalent.

CAUTION:
Never allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.
b. Install position switch to transaxle case, and tighten it to the specified torque. Disassembly And Assembly.
34. Install bracket (2) to transaxle case, and tighten mounting bolt to the specified torque. Disassembly And Assembly.
35. Install selector lever (3) according to following the procedures.
a. Install selector lever to transaxle case.

CAUTION:
Replace selector lever and selector as a set.
b. Install retaining pin to selector lever, using a suitable tool.

CAUTION:
Never reuse retaining pin.
36. Install drain plug according to the following procedures.
a. Install gasket to drain plug.

CAUTION:
Never reuse gasket.
b. Install drain plug to clutch housing, using a suitable tool.
c. Tighten drain plug to the specified torque. Disassembly And Assembly.
37. Install filler plug according to the following procedures.
a. Install gasket to filler plug, and then install them to transaxle case.

CAUTION:
Never reuse gasket.
b. Tighten filler plug to the specified torque. Disassembly And Assembly.

CAUTION:
Fill with gear oil before tighten filler plug to the specified torque.