Disassembly and Reassembly
Countershaft Disassembly and Reassembly
Manual Transaxle Assembly Disassembly and Reassembly
Input Shaft Components
Disassembly
NOTE:
Supporting the gear on the concave side of the puller can cause damage to the gear.
Be sure to support the gear on the flat side of the puller.
1) Remove circlip (1) using special tool and then remove washer.
NOTE:
For smooth removal of circlip, it is recommended to correct tool tips to be flat.
Special Tool
(A): 09900-06107
2) Drive out left bearing (2) and 6th gear (3) using puller (4) and hydraulic press and then remove 5 the gear spacer.
CAUTION:
Using an inappropriate hydraulic press or bearing puller could cause personal injury.
Make sure that both the hydraulic press and bearing puller are capable of safely bearing a load of at least 5 tons (11,000 lbs).
3) Apply puller (3) to 4th gear (2) and drive out 5th gear (1) with 4th gear using hydraulic press.
4) Remove circlip (1) using special tool.
NOTE:
For smooth removal of circlip, it is recommended to correct tool tips to be flat.
Special Tool
(A): 09900-06107
5) Apply puller (3) to 2nd gear (2) and drive out 3rd gear (1) with 2nd gear using hydraulic press.
6) Apply puller (4) to reverse gear (3) and drive out low speed synchronizer sleeve & hub assembly (1), 1st gear (2) with reverse gear using hydraulic press.
7) In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part "a" of right bearing as illustrated till it becomes thin.
NOTE:
The shaft (3) will be damaged if the bearing is ground too much.
Limit the amount of grinding to the minimum amount necessary.
8) Break with a chisel (1) the thin ground right bearing (2) and it can be removed.
Reassembly
Countershaft Inspection
Gear Shift Shaft and Fork Inspection
1) Fit low speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
NOTE:
No specific direction is assigned to low speed synchronizer hub and each key but it is assigned as assembly.
Synchronizer key installation position
2) Drive in reverse gear (1) to countershaft (2) using puller (3) and hydraulic press.
3) Drive in 1st gear spacer (1) using special tool and hydraulic press.
Special Tool
(A): 09940-54910
4) Install 1st gear needle bearing (4), apply oil to it, then install 1st gear and 1st gear synchronizer ring (2).
5) Drive in low speed sleeve & hub assembly (1) using special tool and hydraulic press.
NOTE:
- Support lower speed synchronizer hub with special tool as shown in figure so that retainer of bearing cone will be free from compression.
- Make sure that synchronizer ring key slots are aligned with keys (5) while press-fitting sleeve & hub assembly.
- Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.
Special Tool
(A): 09944-77030
6) Drive in 2nd gear spacer (1) using special tool and hydraulic press.
Special Tool
(A): 09945-55410
7) Drive in 3rd gear (3), 2nd gear and 2nd gear synchronizer ring (1) using special tool and hydraulic press.
NOTE:
It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively.
Special Tool
(A): 09944-77030
8) Select new circlip (1) that will make thrust clearance "a" of bearing 0.15 mm (0.0059 in) or less and install it.
Available circlip thickness
9) Drive in 4th gear (1) using puller and hydraulic press.
10) Drive in 5th gear using the same procedure at step 7).
11) Drive in 6th gear (1) and 5th gear spacer (2) using special tool and hydraulic press.
Special Tool
(A): 09945-55410
12) Install countershaft left bearing (1) and washer using special tool and hydraulic press.
Special Tool
(A): 09913-84510
13) Install countershaft right bearing (1) using special tool and hydraulic press.
Special Tool
(A): 09913-84510
14) Select new circlip (1) that will make thrust clearance "a" of bearing 0.1 mm (0.0039 in) or less and install it.
Available circlip thickness
