Disassembly
Precaution1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and verify that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
5th/Reverse Gear and Housing Parts
1. Disassemble in the order shown in the image, referring to Disassembly Note
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.10 - 0.22 mm (0.0039 - 0.0087 in.)
Maximum: 0.27 mm (0.0106 in.)
2. If the clearance exceeds the maximum, check the contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly note
Locknut
1. Mount the transaxle on the SST.
2. Lock the primary shaft with the SST.
3. Shift to 1st or 2nd gear to lock the rotation of the primary shaft.
CAUTION: Do not reuse the removed locknut.
4. Uncrimp the tabs of the locknuts.
5. Remove the locknuts from the primary and secondary shafts.
Shift fork and shift rod assembly
1. Align the ends of the interlock sleeve and of the control lever (arrow). Turn the shift rod counterclockwise.
2. While holding the 1st-2nd shift fork with one hand and the 3rd-4th shift fork with the other, raise them both at the same time and shift each of the clutch hub sleeves.
3. Lift the control end and remove the steel ball, and, at the same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each of the clutch hub sleeves.
Clutch Housing and Transaxle Case Components
CAUTION: Do not remove an oil seal if not necessary.
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Bearing outer race (transaxle case)
NOTE: If It is difficult to remove the bearing outer race, remove It with the SST.
1. Remove the bearing outer race.
Bearing outer race (secondary shaft)
1. Remove the bearing outer race by lifting out the funnel and race together.
Roll pin
1. Align the groove for removal of the clutch housing pin with the position of the roll pin, then tap the pin out using a pin punch.
Bearing outer race (differential)
CAUTION: Hold the SST with one hand so that it does not fall.
1. Remove the bearing outer race with a press.
Oil seal
Replacement (On-vehicle)
Jack up the vehicle and support it with safety stands. Drain the transaxle oil. Next, use the following procedure to replace the driveshaft oil seal:
1. Remove the front wheel.
2. Remove the splash shield.
3. Separate the front stabilizer from the lower arm.
CAUTION: Do not damage the dust boots.
4. Remove the clinch bolt and pull the lower arm downward. Separate the knuckle from the lower arm ball joint.
5. Loosen the nut and disconnect the tie-rod end with the SST.
CAUTION: Do not subject the tripod joint to shock when removing the driveshaft.
6. Disconnect the driveshaft from the transaxle by prying with a bar between the outer ring and the transaxle.
7. Suspend the driveshaft with a rope.
8. Remove the oil seal with a screwdriver.
NOTE:
- Tap in until the oil seal installer contacts the case.
- Coat the oil seal lip with transaxle oil.
9. Tap the new oil seal into the transaxle case with the SST.
10. Replace the driveshaft end clip with a new one. Insert the driveshaft with the end-gap of the clip facing upward.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Measure the thrust clearance of all gears before disassembly, referring to Pre-inspection.
2. Disassemble in the order shown in the image, referring to Disassembly Note.
1. 3rd/4th shift fork
2. Interlock sleeve
3. Roll pin
4. Control end
5. 1st/2nd shift fork
6. Roll pin
7. Control lever
8. Control rod
9. Bearing inner race
10. Secondary 4th gear
11. Retaining ring
12. Secondary 3rd gear
13. 2nd gear
14. Synchronizer ring (2nd)
15. Retaining ring
16. Clutch hub assembly (1st/2nd)
17. Synchronizer ring (1st)
18. 1st gear
19. Bearing inner race
20. Secondary shaft
21. Bearing inner race
22. 4th gear
23. Synchronizer ring (4th)
24. Retaining ring
25. Clutch hub assembly (3rd/4th)
26. Synchronizer ring (3rd)
27. 3rd gear
28. Bearing inner race
29. Primary shaft
30. Synchronizer spring
31. Synchronizer key
32. Clutch hub
33. Clutch hub sleeve (reverse gear)
34. Synchronizer spring
35. Synchronizer key
36. Clutch hub
37. Clutch hub sleeve
Pre-inspection
Thrust clearance
1. Measure the clearance between the 2nd gear and secondary 3rd gear.
Clearance: 0.175 - 0.455 mm (0.0069 - 0.0179 in.)
Maximum: 0.505 mm (0.0199 in.)
2. Measure the clearance between the 1st gear and differential drive gear.
Clearance: 0.05 - 0.28 mm (0.002 - 0.011 in.)
Maximum: 0.33 mm (0.0130 in.)
3. Measure the clearance between the 4th gear and bearing inner race.
Clearance: 0.1 65 - 0.365 mm (0.0065 - 0.0144 in.)
Maximum: 0.415 mm (0.0163 in.)
4. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05 - 0.20 mm (0.002 - 0.008 in.)
Maximum: 0.25 mm (0.010 in.)
Disassembly note
Bearing inner race and secondary 4th gear
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race and secondary 4th gear with the SST.
Secondary 3rd gear and 2nd gear
1. Remove the retaining ring.
2. Shift the gears to 1st gear.
CAUTION: Hold the shaft with one hand so that It does not fall.
3. Remove the secondary 3rd gear and 2nd gear with the SST.
Clutch hub assembly (1st/2nd), synchronizer ring (1st), and 1st gear
1. Remove the retaining ring.
CAUTION: Hold the shaft with one hand so that it does not fall.
2. Remove the clutch hub assembly (1st/2nd), synchronizer ring (1st), and 1st gear with a press.
Bearing inner race (secondary shaft end)
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race with the SST.
Bearing inner race (4th gear end)
CAUTION: Hold the shaft with one hand so that it does not fall.
1. Remove the bearing inner race with the SST.
Clutch hub assembly (3rd/4th), synchronizer ring (3rd) and 3rd gear
1. Remove the retaining ring.
CAUTION: Hold the shaft with one hand so that it does not fall.
2. Remove the clutch hub assembly (3rd/4th) synchronizer ring (3rd) and 3rd gear with the SST.
Bearing inner race (primary shaft end)
1. Remove the bearing inner race with the SST.