Basic Subassembly Separation

BASIC SUBASSEMBLY SEPARATION



1. REMOVE RELEASE FORK, BEARING BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR




2. REMOVE RELEASE BEARING RETAINER




3. REMOVE ENGINE MOUNT BRACKET AND SELECTING BELLCRANK
a. Remove the 3 bolts and engine mount bracket.
b. Remove the 2 bolts and selecting bellcrank.




4. REMOVE TRANSMISSION CASE COVER
a. Remove the 8 bolts.
b. Using a plastic hammer, tap off the transmission case cover.




5. REMOVE LOCK BALL ASSEMBLY AND PLUG
a. Remove the lock ball.




b. Using a hexagon wrench, remove the plug.




6. REMOVE SHIFT AND SELECT LEVER ASSEMBLY




7. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear double meshing.




c. Remove the lock nut clockwise and remove it.

HINT : The lock nut has LH threads.

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 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-40010




10. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)




11. MEASURE 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.

Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft.




12. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
a. Using 2 screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No.3 clutch hub with synchronizer ring.
SST 09950-30010
c. Remove the 5th gear.
13. REMOVE NEEDLE ROLLER BEARING




14. REMOVE REAR BEARING RETAINER




15. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the 2 snap rings.

HINT : If it is difficult to remove the snap rings, pull up the shafts.




16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




18. REMOVE TRANSMISSION CASE
a. Remove the 17 bolts.
b. Using a plastic hammer, tap off the transmission case.




19. REMOVE REVERSE IDLER GEAR AND SHAFT
a. Pull out the shaft.
b. Remove the idler gear and thrust washer.




20. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the 2 bolts and pull off the reverse shift arm.




21. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY
Remove the input shaft assembly and output shaft assembly together with the No.1 fork shaft, shift head and shift forks with the interlock pin from the transaxle case.




22. REMOVE DIFFERENTIAL CASE ASSEMBLY




23. REMOVE MAGNET FROM TRANSAXLE CASE




24. REMOVE NO.2 FORK SHAFT
a. Using a hexagon wrench, remove the straight screw plug.




b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the shaft.




25. SEPARATE NO.1 FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE SHIFT FORK
a. Mount the shift forks to the vise.
b. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft.




c. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft as shown in the illustration.




d. Separate the No.1 shift fork shaft, No.1 shift head, No.1, No.2 shift forks and reverse shift fork.




26. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB
a. Remove the No.5 synchronizer ring with key spring from No.3 clutch hub.




b. Using a screwdriver, remove the snap ring.

HINT : Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

c. Remove the synchronizer rings.