Transmission Assembly

TRANSAXLE ASSEMBLY


Disassembly

1. Remove drain plug and gasket from clutch housing, using a socket [Commercial service 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 mounting bolts (Black Arrow).





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





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





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), as per the following procedure.
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 pin punch.
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 remover
[Commercial service tool].





25. Remove mainshaft rear bearing outer race from transaxle case, using a remover [Commercial service 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 an oil seal remover.

CAUTION:
Never damage clutch housing.





29. Remove mainshaft front bearing outer race (1) from clutch housing, using the puller (A) [SST: KV381054S0 (J-34286)] and a spacer (B) [Commercial service tool].
30. Remove oil channel (2) from clutch housing.





31. Remove bushing (1) from clutch housing, using a remover
[Commercial service tool].





32. Remove 2 way connector (1) from clutch housing.
33. Remove plug from clutch housing.





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