Part 2 of 3

Transaxle Disassemble Con't





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





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





42. Remove the 3 transmission case retaining bolts.





43. Remove the 13 transaxle case retaining bolts.





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





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





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





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





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





49. Remove the 3 gear shift fork set bolts.





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





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





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





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





55. Remove the No.3 gear shift fork shaft from the reverse shift fork from the transaxle case.
56. Remove the reverse shift fork.





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





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





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





60. Remove the magnet from the transaxle case.





61. Disassemble the No.3 clutch hub assembly.





62. 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.





63. 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.





64. 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.





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





66. If necessary, remove the input shaft bearing.





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





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





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





70. Using a feeler gage, measure the thrust clearance for 3rd and 4th gears of the input shaft.
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 inch). 4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).





71. Using a dial indicator, measure the radial clearance between the gears and the shaft.
3rd and 4th gear radial clearance: 0.15 - 0.58 mm (0.0006 - 0.0023 inch).
72. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.





73. Remove the input shaft snap ring.





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





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





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





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





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





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





80. Remove the roller bearing from the input shaft.