Part 1

TRANSAXLE ASSEMBLY


Disassembly and Assembly


COMPONENTS

Case and Housing Component











Gear Component





















Shift Control Component











Final Drive Component











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





3. Remove rear housing and O-ring.

CAUTION:
Remove to axial direction of input shaft (Backward Black Arrow) because rear housing oil channel is inserted to input shaft center hole.





4. Shift control shaft shift lever (1) to the 3rd gear position.

NOTE:
- If it is not shifted to the 3rd gear position, transaxle case cannot be removed from clutch housing.
- The 3rd gear position means that control shaft select lever is fully rotated clockwise and it is returned approximately 10 degrees.





5. Remove 5th-reverse shift fork (1) and 5th-reverse coupling sleeve according to the following procedures.
a. Remove retaining pin from 5th-reverse shift fork using a suitable tool (A).
b. Press 5th-reverse shift fork, shift to 5th, and then engage it with
3rd gear.
c. Remove bolt (B).
d. Remove nut (C) and washer.

CAUTION:
Never use an impact wrench for removal, or otherwise each gear may be damaged.
e. Remove 5th-reverse shift fork and 5th-reverse coupling sleeve from 5th-reverse synchronizer hub.





6. Remove 5th-reverse synchronizer hub from input shaft using a suitable tool.

CAUTION:
Set claw of the puller to the wider side of the hub when setting the puller in 5th-reverse synchronizer hub.
7. Remove synchronizer levers, 5th-reverse baulk ring, 5th input gear, bushing, and adapter plate from input shaft.





8. Remove 5th main gear from mainshaft using the pullers.










9. Remove position switch from transaxle case.





10. Remove transaxle case bolts (Black Arrow).
11. Remove transaxle case from clutch housing.





12. Remove spacer (1) and 4th main gear (2) from mainshaft.





13. Remove 5th-reverse fork rod (1) according to the following procedures.
a. Pull 5th-reverse fork rod up until it contacts claw (Broken Circle) of reverse gear assembly (2).
b. Press gear portion of reverse gear assembly down, and then remove 5th-reverse fork rod from clutch housing.





14. Remove 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve
(2), and input shaft assembly (3) according to the following procedures.
a. Remove 4th baulk ring, insert keys, and springs from mainshaft.
b. Pull gear of reverse gear assembly (4) up.
c. Pull 1st-2nd fork rod (5) up, and then maintain the neutral position.
d. Remove 3rd-4th fork rod assembly, 3rd-4th coupling sleeve, and input shaft assembly from clutch housing at the same time.
15. Remove retaining pin from 3rd-4th shift fork using a suitable tool.
16. Remove 3rd-4th shift fork from 3rd-4th shift fork rod.





17. Remove lock pins (Black Arrow) from clutch housing.





18. Remove 1st-2nd fork rod assembly (1) and mainshaft assembly
(2) from clutch housing at the same time.
19. Remove retaining pin from 1st-2nd shift fork using a suitable tool.
20. Remove 1st-2nd shift fork from 1st-2nd shift fork rod.





21. Remove retaining pin from reverse gear assembly using a suitable tool.
22. Remove reverse gear assembly from clutch housing.





23. Remove final drive assembly (1) from clutch housing.
24. Remove plug from the clutch housing (with ABS models).
25. Remove the vehicle speed sensor (without ABS models).
26. Remove pinion shaft and pinion gear from clutch housing.
27. Remove magnet and dowel pins (2) from clutch housing.





28. Remove input shaft front bearing from clutch housing using a suitable tool.





29. Cut oil channel tube at the root.
30. Remove mainshaft front bearing and oil channel from clutch housing using Tool (A).










31. Remove bushings (1) from clutch housing using a suitable tool.





32. Remove differential side oil seals (1) from clutch housing and transaxle case using a suitable tool.

CAUTION:
Never damage transaxle case and clutch housing.





33. Remove differential side bearing outer races (1) from clutch housing and transaxle case using a suitable tool.

CAUTION:
Never damage transaxle case and clutch housing.





34. Pull two way connector (1) straight to remove it from air breather inner tube (2).
35. Remove air breather inner tube from transaxle case.





36. Remove bushings (1) from transaxle case using a suitable tool.
37. Remove retaining pin (Black Arrow) from selector using a suitable tool.
38. Remove selector from control shaft.
39. Remove oil gutter from transaxle case.





40. Remove bolt (Black Arrow), and then remove bushing, spring, and gear catch from transaxle case.
41. Remove check ball plug from transaxle case.





42. Remove bolts (Black Arrow), and then remove control shaft (1) from transaxle case.
43. Remove O-ring from control shaft.





44. Expand snap rings (1) and remove input shaft rear bearing and mainshaft rear bearing from transaxle case using Tool (A).





45. Remove snap rings from transaxle case.
46. Remove check balls (2) from transaxle case.