Basic Subassembly Separation

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BASIC SUBASSEMBLY SEPARATION
1. Remove release fork and bearing.

INSTALLATION HINT: Apply molybdenum disulphide lithium base grease.

2. Remove bolt and vehicle speed sensor driven gear.
Torque: 11 N.m (8 ft. lbs.).
3. Remove back-up light switch.
Torque: 40 N.m (30 ft. lbs.).
4. Remove selecting bellcrank assembly.
a. Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N.m (18 ft. lbs.).
b. Remove the control bellcrank dust cover from the selecting bellcrank assembly.
5. Remove control lever housing support bracket.
- Remove the 3 bolts and bracket.
Torque: 11 N.m (8 ft. lbs.).





6. Remove clutch release bearing retainer.
- Using a torx wrench (T30), remove the 3 torx screws and retainer.
Torque: 11 N.m (8 ft. lbs.).





7. Remove transmission case cover.
a. Remove the 9 bolts.
Torque: 18 N.m (13 ft. lbs.).
b. Using a brass bar and hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case, and remove the transmission case cover.
Formed In Place Gasket (FIPG): THREE BOND 1281 or equivalent





8. Remove shift and select lever shaft assembly.
a. Remove the lock bolt.
Torque: 29 N.m (22 ft. lbs.).
b. Remove the 4 bolts and pull out the shift and select lever shaft assembly with the gasket.
- Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 N.m (14 ft. lbs.).





9. Remove lock nut.
a. Engage the gear double meshing.
b. Using a chisel and hammer, loosen the staked part or, the nut.
c. Remove the lock nut.
Torque: 118 N.m (87 ft. lbs.).
d. Disengage the gear double meshing.





10. Remove No. 3 hub sleeve and No. 3 shift fork.
a. Remove the bolt from the No.3 shift fork.
Torque: 16 N.m (12 ft. lbs.).
b. Remove the No.3 hub sleeve and shift fork.

INSTALLATION HINT: Using SST and a hammer, drive in the No.3 hub sleeve with the shift fork.

SST 09636-20010

INSTALLATION NOTICE: Align the synchronizer ring slots with the shifting keys.





11. Inspect 5th gear thrust clearance.
- Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10-0.57 mm (0.0039-0.0224 inch).
Maximum clearance: 0.65 mm (0.0256 inch).





12. Inspect 5th gear radial clearance.
- Using a dial indicator, measure the radial clearance.
Standard clearance: 0.015-0.058 mm (0.0006-0.0023 inch).
Maximum clearance: 0.070 mm (0.0028 inch).
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





13. Remove No.3 clutch hub and 5th gear.
a. Using 2 screwdrivers and a hammer, tap out the snap ring.





INSTALLATION HINT: Select a snap ring that will allow minimum axial play.

b. Using a screwdriver, remove the key spring.





c. Install a bolt and washer to the tip of the input shaft and using SST, remove the No.3 clutch hub.
SST 09950-30010

NOTICE: Select a bolt whose outer diameter is smaller than the screw hole of the input shaft so that it can be turned easily.

d. Remove the synchronizer ring, 5th gear and needle roller bearing.





14. Remove 5th driven gear.
- Using SST, remove the 5th driven gear.
SST 09628-62011, 09950-40010 (09957-04010), 09950-60010 (09951-00230)





INSTALLATION HINT: Using SST, install the 5th driven gear.

SST 09309-12020





15. Remove rear bearing retainer.
- Remove the 5 bolts and retainer.
Torque: 27 N.m (20 ft. lbs.).
16. Remove bearing snap ring.
- Using a snap ring expander, remove the 2 snap rings.

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





17. Remove reverse idler gear shaft lock bolt.
Torque: 29 N.m (22 ft. lbs.).
18. Remove snap ring from no. 2 shift fork shaft.
- Using 2 screwdrivers and a hammer, tap out the snap ring.





19. Remove plug, seat, spring and ball.
a. Using a hexagon wrench, remove the 3 plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 25 N.m (18 ft. lbs.).
b. Using a magnetic finger, remove the 3 seats, springs and balls.





20. Remove lock ball assembly.
- Using a hexagon wrench, remove the lock ball assembly.
Sealant: THREE BOND 1344 LOCTITE 242 or equivalent
Torque: 39 N.m (29 ft. lbs.).





21. Remove transmission case.
a. Remove the 16 bolts.
Torque: 29 N.m (22 ft. lbs.).
b. Using a plastic hammer, carefully tap the projection of the transmission case to remove the transmission case from the transaxle case, and remove the transmission case.





Formed In Place Gasket (FIPG): THREE BOND 1281 or equivalent





22. Remove reverse idler gear, thrust washer and shaft.
23. Remove reverse shift arm bracket.
- Remove the 2 bolts and bracket.
Torque: 17 N.m (13 ft. lbs.).





INSTALLATION HINT: Install the reverse idler gear, thrust washer and shaft, as shown.





24. Remove shift fork and shift fork shaft.
a. Using 2 screwdrivers and a hammer, tap out the 3 snap rings.
b. Remove the 3 set bolts.
Torque: 16 N.m (12 ft. lbs.).
c. Pull up the No.3 shift fork shaft, remove the No.2 shift fork shaft and shift head.





d. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
e. Remove the No.3 shift fork shaft and reverse- shift fork.
f. Pull out the No.1 shift fork shaft.
g. Remove the No.1 and No.2 shift forks.
25. Remove input and output shafts together from transaxle case.
26. Remove differential case assembly.

INSTALLATION HINT: Before assembly, inspect the differential side bearing preload.

27. Remove magnet from transaxle case.
28. Remove No.3 hub sleeve, shifting key and spring from No.3 clutch hub.
- Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.3 clutch hub.