1-55

Transaxle Disassemble





1. Remove the filler plug and gasket.





2. Remove the drain plug and gasket.





3. Remove the bolt and speedometer drive hole cover.





4. Remove the backup light switch and gasket from the transaxle case.





5. Remove the 3 bolts and the control cable bracket.





6. Remove the 2 bolts and the selecting bellcrank assembly.
7. Install the guide bushing (1) in the shift lever.





8. Remove the lock ball assembly from the transaxle case.





9. Remove the 4 bolts (1) and the select lever shaft assembly from the transaxle case.





10. Remove the 9 transmission case cover bolts.





11. Using a brass bar and hammer, carefully tap on the tabs of the transmission case cover to remove the cover from the transmission case.





12. Using a dial indicator, measure the thrust clearance of 6th gear.

Thrust Clearance
Standard thrust clearance should be between 0.10 - 0.60 mm (0.0039 - 0.0236 inch). Maximum clearance should not exceed 0.60 mm (0.0236 inch).





13. Using a dial indicator, measure the radial runout of 6th gear.

Thrust Clearance
Standard radial runout should be between 0.009 - 0.50 mm (0.0003 - 0.0020 inch). Maximum runout should not exceed 0.50 mm (0.0020 inch).
14. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.





15. Remove the 6th driven gear snap ring from the output shaft.





16. Using a 2 jaw puller or equivalent, remove the rear bearing assembly, 6th driven gear from the output shaft.





17. Remove the spacer from the output shaft.





18. Remove the input shaft snap ring.





19. Using a 2 jaw puller or equivalent, remove the rear bearing assembly, 6th driven gear from the input shaft.





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





21. Remove the 6th gear synchronizer ring.





22. Remove the bolt, No.3 gear shift fork and No.3 hub sleeve.





23. Using a dial indicator, measure the thrust clearance of 5th gear.

Thrust Clearance
Standard thrust clearance should be between 0.10 - 0.62 mm (0.0039 - 0.0244 inch). Maximum clearance should not exceed 0.62 mm (0 0244 inch).





24. Using a dial indicator, measure the radial runout of 6th gear.

Thrust Clearance
Standard radial runout should be between 0.015 - 0.056 mm (0.0006 - 0.0022 inch). Maximum runout should not exceed 0.56 mm (0.0022 inch).
25. If the gear exceeds any of the maximum measurements, replace the gear. roller bearing or shaft.





26. Remove the 5th gear snap ring from the shaft.





27. Using a puller, remove the No.3 clutch hub assembly.





28. Remove 5th gear and the 5th gear synchronizer ring from the input shaft.





29. Remove the snap ring from the output shaft.





30. Remove the roller bearing and 2 spacers.





31. Using a puller, remove the 5th driven gear.





32. Remove the 5 rear bearing retainer bolts.
33. Remove the rear bearing retainer from the transaxle case.





34. Using snap ring pliers or equivalent, remove the 2 snap rings.





35. Remove the reverse idler gear shaft lock bolt and gasket from the transaxle case.





36. Remove the snap ring from the No.2 shift fork shaft.





37. Using a Allen wrench or equivalent, remove the 3 screw plug assemblies from the transaxle case





38. Using a Allen wrench or equivalent, remove the 2 screw plugs from the transaxle case





39. Remove the 3 transmission case retaining bolts.





40. Remove the 13 transaxle case retaining bolts.





41. Using a brass bar and hammer, carefully tap the tabs on the case in order to separate the case halves.





42. Remove the 2 bolts and the oil receiver pipes from the transaxle case.





43. Remove the 2 reverse shift arm bracket retaining bolts, then remove the bracket.





44. Remove the reverse idler gear, thrust washer and shaft.





45. Remove the 2 snap rings from the No.1 and No.2 gear shift fork shafts.





46. Remove the 3 gear shift fork set bolts.





47. Remove the No.2 gear shift fork shaft from the No.2 gear shift fork.
48. Remove the No.1 gear shift head, No.1 gear shift fork and the reverse shift fork from the transaxle case.





49. Remove the No.1 gear shift fork shaft from the No.1 gear shift fork from the transaxle case.





50. Remove the No.1 gear shift head from the shift shaft.





51. Remove the No.1 gear shift fork from the reverse gear assembly.





52. Remove the No.3 gear shift fork shaft from the reverse shift fork from the transaxle case,
53. Remove the reverse shift fork.





54. Remove the No.2 gear shift fork from the No.2 hub sleeve groove.





55. Remove the input and output shafts together from the transaxle case.