Component Parts Removal

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH
Using SST, remove the back-up light switch.
SST 09817-16011




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 LEVER
a. Remove the shift lever set nut.




b. Using a pin punch and hammer, tap out the lock pin.




6. REMOVE LOCK BOLT




7. REMOVE CONTROL SHAFT COVER
Remove the bolts holding the control shaft cover.




8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY




9. REMOVE TRANSMISSION CASE COVER




10. REMOVE BREATHER PLUG WITH GASKET




11. 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.




12. 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.




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




14. 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.)




15. 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)
16. REMOVE NEEDLE ROLLER BEARING AND SPACER




17. 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.




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




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




19. 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.




20. REMOVE REVERSE IDLER GEAR SHAFT RETAINING BOLT




21. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.
(Transmission case side: fourteen bolts)
(Transaxle case side: three bolts)




22. REMOVE OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE
a. Remove the shim.




b. Using SST and a hammer, remove the output shaft rear tapered roller bearing outer race.
SST 09316-60010 (09316-00010)




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




24. REMOVE REVERSE SHIFT ARM BRACKET
Remove the bolt and pull off the bracket.




25. REMOVE REVERSE IDLER GEAR AND SHIFT
Pull out the shift, remove the reverse idler gear.




26. 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.




27. REMOVE THREE SET BOLTS




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




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




30. 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.




31. 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.




32. 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 ring from the No.1, No.2 and No.3 shift fork shafts.




33. 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.




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




b. Remove the differential case assembly.




35. REMOVE MAGNET FROM TRANSAXLE CASE




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




b. Remove the two bolts and oil pump.