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:
- Do not damage clutch housing and transaxle case.
- Do not reuse differential side oil seals.





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

CAUTION:
Do not damage clutch housing.





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

CAUTION:
Do not 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.

CAUTION:
Do not reuse bushings.





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.

CAUTION:
Do not reuse snap ring and oil channel.





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

CAUTION:
- Do not damage clutch housing.
- Do not reuse input shaft oil seal.





29.Remove mainshaft front bearing outer race (1) from clutch housing, using Tool (A) and a suitable tool (B).
Tool number: KV-381054S0 (J-34286)
30.Remove oil channel (2) from clutch housing.





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

CAUTION:
Do not reuse bushing.





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





34.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.





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





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

CAUTION:
Do not reuse bushings.
5.Install oil channel to clutch housing.

CAUTION:
Do not reuse oil channel.





6.Install mainshaft front bearing outer race to clutch housing, using Tool (A).
Tool number: KV-38100200 (-)

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





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

CAUTION:
Do not reuse input shaft oil seal.
Tool number: ST-33220000 (-)





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

CAUTION:
- Do not reuse snap ring and oil channel.
- Select and install snap ring that has the same thickness as previous one.
- Replace transaxle assembly when replacing transaxle case.
9.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.
- Do not reuse 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).





10.Install mainshaft rear bearing outer race to transaxle case, using
Tool (A).
Tool number: KV-38100200 (-)

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





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

CAUTION:
Do not reuse bushings.





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





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

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

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





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

CAUTION:
Do not reuse retaining pin.
16.Install shim to transaxle case.





17.Install differential side bearing outer race (transaxle case side)
to transaxle case, using Tool (A).
Tool number: ST-33400001 (J-26082)

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





18.Install differential side bearing outer race (clutch housing side) to clutch housing, using Tool (A).
Tool number: KV-38100200 (-)

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





19.Install differential side oil seals (1) to clutch housing and transaxle case, using Tool.
Tool number: KV-32500QAA (B.vi 1666-B)





Dimension (L1): 1.2 - 1.8 mm (0.047 - 0.071 in)
Dimension (L2): 2.7 - 3.3 mm (0.106 - 0.130 in)

CAUTION:
- Do not reuse differential side oil seal.
- Do not incline differential side oil seal.
- Do not damage clutch housing and transaxle case.
20.Install magnet to clutch housing.
21.Install final drive assembly to clutch housing.





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





23.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.





24.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.





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

CAUTION:
Replace selector lever and selector as a set.





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

CAUTION:
- Do not 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.





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





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

CAUTION:
Do not reuse seal washer.
b.Tighten reverse idler shaft bolt to the specified torque. Refer to
.





31.Tighten transaxle case bolts () to the specified torque. .





32.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:
Do not 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. .
33.Install bracket (2) to transaxle case, and tighten bolt to the specified torque. .
34.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:
Do not reuse retaining pin.
35.Install drain plug according to the following procedures.
a.Install gasket to drain plug.

CAUTION:
Do not reuse gasket.
b.Install drain plug to clutch housing, using a suitable tool.
c.Tighten drain plug to the specified torque. .
36.Install filler plug according to the following procedures.
a.Install gasket to filler plug, and then install filler plug to transaxle case.

CAUTION:
Do not reuse gasket.
b.Tighten filler plug to the specified torque. .

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