Part 1 of 3

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.
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.
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. Install the 5th driven gear puller DT-47947 as shown.





22. Install the harmonic balancer puller J-24420-C to DT-47947, then remove the 5th driven gear from the transaxle assembly.





23. Using the bolts from DT-47947 and harmonic balancer puller J-24420-C, remove the synchronizer hub from the transaxle assembly.





24. Remove the 6th gear synchronizer ring.





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





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





27. Using a dial indicator, measure the radial runout of 6th gear.
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).
28. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.





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





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





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





32. Remove the snap ring from the output shaft.





33. Remove the roller bearing and 2 spacers.





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





35. Remove the 5 rear bearing retainer bolts.
36. Remove the rear bearing retainer from the transaxle case.





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





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





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