Disassembly and Reassembly
Input Shaft Disassembly and Reassembly
Manual Transaxle Assembly Disassembly and Reassembly
Input Shaft Components
Disassembly
1) 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
2) Remove input shaft right bearing (2) and left bearing (4) from input shaft (1) using bearing puller (3) and hydraulic press.
3) Drive out 6th gear spacer (1), and 6th gear (2) all at once using puller (3) and hydraulic press.
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.
4) Drive out 5th and 6th synchronizer sleeve & hub assembly (1) together with 5th gear (2) using puller (3) and hydraulic press.
5) Take out 5th gear needle bearing from input shaft.
6) Drive out input shaft 5th gear spacer according to the following procedure.
a) Engage high speed synchronizer sleeve to input shaft 4th gear.
b) Push down input shaft (1) a little using puller (2) and hydraulic press.
c) Drive out 5th gear spacer (1) using puller (2) and hydraulic press.
7) Take out 4th gear, 4th gear synchronizer ring and 4th gear needle bearing from input shaft.
8) 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
9) Drive out high speed synchronizer sleeve & hub assembly (1) together with 3rd gear (2) using puller (3) and hydraulic press.
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.
10) Take out 3rd gear needle bearing from input shaft.
11) Disassemble synchronizer sleeve & hub assembly.
Reassembly
Input Shaft Inspection
Gear Shift Shaft and Fork Inspection
1) Drive in right bearing (1) to input shaft (2) using special tool and hydraulic press.
Special Tool
(A): 09941-74910
2) Fit high speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
NOTE:
- No specific direction is assigned to each key but it is assigned as sleeve & hub assembly.
- Size of high speed synchronizer sleeve and hub are the smaller than those of low speed one.
Synchronizer key installation position
3) Install 3rd gear needle bearing (4), apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
4) Drive in high speed sleeve & hub assembly (3) using special tool and hydraulic press and then install circlip.
NOTE:
- While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys (5) in sleeve & hub assembly.
- Check free rotation of 3rd gear after press-fitting sleeve & hub assembly.
Special Tool
(A): 09944-77030
5) Install 4th gear needle bearing (2), apply oil to it, then install 4th gear (3) and synchronizer ring (4).
6) Drive in 5th gear spacer (1) using special tool and hydraulic press.
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).
Special Tool
(A): 09940-54910
(B): 09913-85210
7) Install 5th gear needle bearing, apply oil to it, then install 5th gear and synchronizer ring.
8) Fit 5th & 6th gear synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
NOTE:
- No specific direction is assigned to 5th & 6th gear synchronizer hub or each key but it is assigned as assembly.
- Size of 5th & 6th gear synchronizer sleeve and hub are the smaller than those of high speed one.
Synchronizer key installation position
9) Drive in 5th and 6th gear synchronizer sleeve & hub assembly (1) using special tool and hydraulic press.
Special Tool
(A): 09913-85210
10) Install 6th gear needle bearing (1), apply oil to it, then install 6th gear (2) and synchronizer ring (3).
11) Using same special tool at step 9), drive in 6th gear spacer (4).
12) Using same special tool at step 9), press-fit left bearing (1).
13) Select circlip (1) that will make thrust clearance "a" of bearing 0.1 mm (0.004 in) or less and install it.
Available circlip thickness
