56-113

Transaxle Disassemble Continued





56. Remove the differential case assembly from the transaxle case.





57. Remove the magnet from the transaxle, case.





58. Disassemble the No.3 clutch hub assembly.





59. Check the 5th and 6th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





60. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.





61. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.89 mm (0.0350 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.





62. Remove the bolt and the transaxle case receiver from the transaxle case.





63. If necessary, remove the input shaft bearing.





64. If the input shaft bearing has been removed, remove the oil seal.





65. If the output shaft front bearing requires replacement, remove the bolt and output shaft cover.





66. Using a puller, remove the output shaft front bearing.





67. Using a feeler gage, measure the thrust clearance for 3rd and 4th gears of the input shaft.

Standard Clearance
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 inch).
4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).





68. Using a dial indicator, measure the radial clearance between the gears and the shaft.

Standard Clearance
3rd and 4th gear radial clearance: 0.15 - 0.58 mm (0.0006 - 0.0023 inch).
69. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.





70. Remove the input shaft snap ring.





71. Using a press, remove the center ball bearing and 4th gear from the input shaft.





72. Remove the roller bearing and spacer from the input shaft.





73. Remove the 4th gear synchronizer ring from the input shaft.





74. Remove the No.2 hub sleeve snap ring.





75. Using a press, remove the No.2 hub sleeve and 3rd gear from the input shaft.





76. Remove the No.2 3rd gear synchronizer ring.





77. Remove the roller bearing from the input shaft.





78. Disassemble the No.2 hub sleeve assembly.





79. Check the 3rd and 4th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





80. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. 3rd gear minimum clearance is 0.65 mm (0.0256 inch). 4th gear minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.





81. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.





82. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

Minimum Outer Diameter
^ A: 21.991 mm (0.8658 inch)
^ B: 24.885 mm (0.9797 inch)
^ C: 28.985 mm (1.1411 inch)
^ D: 30.985 mm (1.2199 inch)
^ E: 24.985 mm (0.9837 inch)
83. If the out diameter is less than the minimum, replace the input shaft.





84. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 inch).
85. If the runout exceeds the maximum, replace the output shaft.





86. Using a feeler gage, measure the thrust clearance for 1st and 2nd gears of the output shaft.

Standard Clearance
1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 inch).
2nd gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).





87. Using a dial indicator, measure the radial clearance between the gears and the shaft.

Standard Clearance
1st and 2nd gear radial clearance: 0.15 - 0.58 mm (0.0006 - 0.0023 inch).
88. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.





89. Using a press, remove the radial ball bearing and the 4th driven gear from the output shaft.





90. Remove the spacer from the output shaft.





91. Shift the reverse gear into 1st gear.





92. Using a press, remove the 3rd driven gear and 2nd gear from the output shaft.





93. Remove the roller bearing from the output shaft





94. Remove the spacer from the output shaft.





95. Remove the No.2 synchronizer ring from the output shaft.





96. Remove the snap ring from the output shaft.





97. Using a press, remove the reverse gear assembly, 1st gear and the No. 1 synchronizer from the output shaft.





98. Remove the No.1 synchronizer from 1st gear.





99. Remove the roller bearing from the output shaft.





100. Remove the 1st gear thrust washer from the output shaft.





101. Using a magnet, remove the ball from the output shaft.
102. Remove the snap ring from the output shaft.





103. Using a press, remove the front bearing inner race.





104. Disassemble the reverse gear assembly.





105. Check the 1st gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





106. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.





107. Check the 2nd gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





108. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm (0.0276 inch). If the clearance is less than the minimum, replace the synchronizer ring.





109. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.





110. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

Minimum Outer Diameter
^ 1:31.985 mm (1.2592 inch)
^ 2:37.985 mm (1.4955 inch)
^ 3:32.985 mm (1.2986 inch)
111. If the out diameter is less than the minimum, replace the output shaft.





112. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 inch).
113. If the runout exceeds the maximum, replace the output shaft.