Component Parts Removal

COMPONENTS

Part 1:

Part 2:

Part 3:

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH




3. REMOVE SPEEDOMETER DRIVEN GEAR
a. Remove the set bolt and speedometer adaptor.
b. Remove the speedometer driven gear.




4. REMOVE SELECTING BELLCRANK ASSEMBLY




5. REMOVE SHIFT AND SELECT LEVER
a. Remove the lock bolt.




b. Remove the four bolts and pull out the shift and select lever




6. REMOVE TRANSMISSION CASE COVER

7. REMOVE LOCK NUT




a. Unstake the lock nut.
b. Engage the gear double meshing




c. Remove the lock nut.
d. Disengage the gear double meshing.




8. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
a. Remove the No.3 shift fork set bolt.
b. Remove the No.3 hub sleeve and No.3 shift fork.




9. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07040, 09310-07050)

10. MEASURE FIFTH GEAR THRUST CLEARANCE AND OIL CLEARANCE




a. Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)




b. Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

11. REMOVE NO.3 CLUTCH HUB AND FIFTH GEAR




a. Using two screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No.3 clutch hub with synchronizer ring and 5th gear.
SST 09310-17010 (09310-07010, 09310-07020, 09310-07040, 09310-07050)
12. REMOVE NEEDLE ROLLER BEARING AND SPACER




13. REMOVE REAR BEARING RETAINER
a. Using a torx socket wrench, remove the seven torx screws and bearing retainer.
Torx wrench T45 09042-00050
b. Remove the adjust shim.




14. REMOVE SNAP RING
a. Using snap ring pliers, remove the snap ring.




b. Using two screwdrivers and a hammer, remove the three snap rings.




15. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL
a. Using SST, remove the plug.
SST 09313-30021
b. Using a magnetic finger, remove the seat, spring and locking ball.




16. REMOVE REVERSE IDLER GEAR SHAFT RETAINING BOLT

17. REMOVE TRANSMISSION CASE




a. Remove the fourteen bolts from the transmission case side.




b. Remove the three bolts from the transaxle case side and tap off the case with a plastic hammer.




18. REMOVE OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE
Using a plastic hammer, drive out the outer race.




19. REMOVE NO.2 OIL PIPE
a. Remove the gasket.
b. Remove the two bolts and oil pipe.




20. REMOVE REVERSE SHIFT ARM BRACKET
Remove the two bolts and pull off the bracket.




21. REMOVE REVERSE IDLER GEAR AND SHIFT
Pull out the shift, remove the reverse idler gear and thrust washer.




22. REMOVE STRAIGHT SCREW, LOCKING BALLS AND SPRINGS
a. Using SST, remove the two plugs.
SST 09313-30021
b. Using a magnetic finger, remove the two spring seats, springs and balls.




23. REMOVE SET BOLT




24. REMOVE NO.1 SHIFT FORK SHAFT
Pull up No.3 shift fork shaft, remove the No.1 shift fork shaft.




25. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.




26. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK
a. Pull out the No.2 shift fork shaft.
b. Remove the shift head and No.1 shift fork.




27. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK
a. Pull out the No.3 shift fork shaft with reverse shift fork.
b. Remove the No.2 shift fork.




28. REMOVE SNAP RINGS
a. Using two screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft.
b. Using two screwdrivers and a hammer, remove the snap rings from the No.1, No.2 and No.3 shift fork shafts.




29. REMOVE INPUT AND OUTPUT SHAFT ASSEMBLY
a. Leaning the output shaft to the differential side, remove the input shaft assembly




b. Lift up the differential case assembly, remove the output shaft.




30. REMOVE DIFFERENTIAL ASSEMBLY
a. Remove the oil pump drive gear.




b. Remove the differential case assembly.




31. REMOVE MAGNET FROM TRANSAXLE CASE




32. REMOVE OIL PUMP ASSEMBLY
a. Remove the two bolts and oil pipe.




b. Remove the two bolts and oil pump.

INSPECTION OF COMPONENT PARTS




1. INSPECT SYNCHRONIZER RING FOR FIFTH GEAR
a. Check for wear or damage.
b. Turn the ring and push it in to check the braking action.




c. Measure the clearance between the synchronizer ring back and the gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring.




2. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve.




3. REMOVE TRANSAXLE CASE RECEIVER




4. IF NECESSARY, REPLACE INPUT SHAFT BEARING AND OIL SEAL
a. Using SST, pull out the bearing.
SST 09612-65014




b. Using a screwdriver, remove the oil seal.




c. Using SST, drive in a new oil seal.
SST 09608-12010 (09608-00020, 09608-00080)
d. Coat the lip of seal with MP grease.




e. Using SST, drive in a new bearing.
SST 09608-12010 (09608-00020, 09608-00060)




5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT OUTER RACE AND OUTPUT SHAFT COVER
a. Using SST, pull out the outer race.
SST 09308-00010
b. Remove the output shaft cover.




c. Install the output shaft front cover.

HINT: Install the shaft cover projection into the case side groove.




d. Using SST, press in a new outer race.
SST 09316-60010 (09316-00010, 09316-00020)




6. INSTALL AND TORQUE TRANSAXLE CASE RECEIVER

Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)




7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
a. Using SST, pull Out the oil seal.
SST 09921-00010




b. Using SST, drive in a new oil seal.
SST 09201-60011

Drive in depth: 33 mm (1.30 in.)

c. Coat the lip of oil seal with MP grease.




8. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a. Using SST, remove the screw plug.
SST 09313-30021
b. Using a pin punch and hammer, drive out the slotted spring pin.




c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using SST, install the screw plug.
SST 09313-30021