Disassembly and Assembly
Disassembly and AssemblyCase and Housing Components
MT-18 Components:
Gear Components
MT-19 Components (Part 1):
MT-19 Components (Part 2):
MT-19 Components (Part 3):
Shift Control Components
MT-22 Components:
Final Drive Components
DISASSEMBLY
1. Remove drain plug and gasket from clutch housing, and drain oil.
2. Remove filler plug and gasket from transaxle case.
3. Remove CSC from clutch housing.
4. Remove retaining pin from shift lever (1) using suitable tool.
5. Remove bracket (2) and position switch (3) from transaxle case.
6. Remove the bolts.
7. Remove reverse idler shaft bolt (<-) and seal washer.
8. Remove transaxle case (1) upward while rotating control lever (2)
9. Remove spring (1) of selector from return bushing (2).
10. Remove bearing preloading shim from mainshaft assembly.
11. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod (2), and reverse fork rod (3) to neutral position.
12. Remove selector (4) from clutch housing.
13. Remove retaining pin from 5th-6th shift fork using suitable tool.
14. Remove 3rd-4th and 5th-6th fork rod assembly according to the following.
a. Lift the fork rod (1) up.
b. Remove 3rd-4th and 5th-6th fork rod assembly from clutch housing.
15. Remove reverse gear assembly (1) according to the following:
a. Lift the input shaft assembly (2) and mainshaft assembly (3) up.
b. Remove reverse gear assembly (1) and reverse fork rod (4) from clutch housing.
16. Remove spring washer located under the reverse idler shaft.
17. Remove input shaft assembly (1), mainshaft assembly (2), and 1st-2nd fork rod (3) from clutch housing.
18. Remove final drive assembly (1) from clutch housing.
19. Remove magnet from clutch housing.
20. Remove differential side oil seals (1) from clutch housing and transaxle case using suitable tool.
CAUTION: Be careful not to damage clutch housing and transaxle case.
21. Remove differential side bearing outer race (1) from clutch housing using suitable tool.
CAUTION: Be careful not to damage clutch housing.
22. Remove differential side bearing outer race (1) and shim (2) from transaxle case using a brass bar as shown.
CAUTION: Be careful not to damage transaxle case.
23. Remove retaining pin from control lever (1) using suitable tool.
24. Remove control lever.
25. Remove shift finger (1) from transaxle case.
26. Remove control lever oil seal and bushings from transaxle case using suitable tool.
27. Remove oil gutter (1) from transaxle case.
28. Remove shift lever oil seal (1) from transaxle case.
29. Remove bushings (1) from transaxle case using suitable tool.
30. Remove mainshaft rear bearing outer race and shim from transaxle case using suitable tool.
CAUTION: Be careful not to damage transaxle case.
31. Remove snap ring (1) and oil channel (2) from transaxle case.
32. Remove input shaft oil seal (1) from clutch housing using suitable tool.
33. Remove mainshaft front bearing outer race (1) and oil channel (2) from clutch housing using Tool (A) and suitable tool (B).
Tool number: KV381054S0 (J-34286)
34. Remove bushings (1) from clutch housing using suitable tool.
35. Remove two way connector (1) from clutch housing.
36. Remove pinion gear (1) and pinion shaft (2) from clutch housing.
ASSEMBLY
1. Install pinion gear (1) and pinion shaft (2) into clutch housing.
2. Install two way connector (1) into clutch housing.
3. Install bushings (1) until they are flush with end face of clutch housing using suitable tool (A).
4. Install oil channel and mainshaft front bearing outer race into clutch housing using Tool (A).
Tool number KV38100200 ( - )
CAUTION: Do not reuse oil channel.
5. Install input shaft oil seal (1) into clutch housing using Tool (A).
Tool number: ST33220000 ( - )
6. Install snap ring (1) and oil channel (2) onto transaxle case.
7. Install shim and mainshaft rear bearing outer race into transaxle case using Tool (A).
Tool number KV38100200 ( - )
8. Install bushings (1) into transaxle case using suitable tool (A).
9. Install oil gutter (1) onto transaxle case.
10. Install shift lever oil seal (1) and bushing (2) into transaxle case using suitable tool (A).
11. Install control lever oil seal and bushings into transaxle case using suitable tool.
12. Install shift finger (1) into transaxle case.
13. Install control lever (1) and then install retaining pin.
CAUTION: Do not reuse retaining pin.
14. Install shim and differential side bearing outer race into transaxle case using Tool (A).
Tool number ST33400001 (J-26082)
15. Install differential side bearing outer race into clutch housing using Tool (A).
Tool number KV38100200 ( - )
16. Install differential side oil seals (1) into clutch housing and transaxle case using Tool (A).
Tool number KV38100300 (J-25523)
17. Install magnet onto clutch housing.
18. Install final drive assembly into clutch housing.
19. Install input shaft assembly (1), mainshaft assembly (2) and 1st-2nd fork rod assembly (3) into clutch housing.
20. Install spring washer located under the reverse idler shaft.
21. Install reverse gear assembly (1) according to the following:
a. Lift up the input shaft assembly (2) and mainshaft assembly (3).
b. Install reverse gear assembly (1) and reverse fork rod (4) to clutch housing.
22. While lifting up fork rod (1), install 3rd-4th and 5th-6th fork rod assembly to clutch housing.
23. Install retaining pin into 5th-6th shift fork using suitable tool.
CAUTION: Do not reuse retaining pin.
24. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod assembly (2), and reverse fork rod (3) to neutral position.
25. Install selector (4) into clutch housing.
26. Install spring of selector into return bushing.
27. Install bearing preloading shim onto mainshaft assembly.
28. Apply recommended sealant onto the mating surface of transaxle case.
^ Use Genuine Silicone RTV or equivalent.
CAUTION:
^ Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.
^ Check for damage on the mating surface.
^ Apply a continuous bead of liquid gasket to the mating surface.
29. Engage shift finger and selector by moving control lever (1). Install transaxle case to clutch housing.
30. Install seal washer and reverse idler shaft bolt (<---), and then tighten bolt to specification.
CAUTION: Do not reuse seal washer.
31. Tighten bolts to specification.
32. Apply sealant to the threads of position switch (1). Then install it into transaxle case and tighten to specification.
^ Use Genuine Silicone RTV or equivalent.
33. Install bracket (2), and tighten bolt to specification.
34. Install shift lever (3), and then install retaining pin using suitable tool.
CAUTION: Do not reuse retaining pin.
35. Install CSC onto clutch housing.
36. Install a new gasket onto drain plug, and then install it into clutch housing. Tighten drain plug to specification.
37. Install a new gasket onto filler plug, and then install it into transaxle case. Tighten filler plug to specification.
CAUTION:
^ Do not reuse gasket.
^ After oil is filled, tighten filler plug to specification.