Clutch Housing

CLUTCH HOUSING

DISASSEMBLY
1. Remove a shim of input rear and a oil channel.
2. Remove 2 bolts for the reverse bracket.
3. The bracket is raised up while having the reverse coupling by your hand and swing it.
4. You can remove these bracket easily with turning counter clockwise around rev. idler shaft.
5. Then you can remove fork and bracket at same time.





6. Pay attention not to lose the cap.
7. Loosen the reverse check bolts and remove a spring, a rod, and a ball with a magnet tool.





8. The next, remove the reverse rod with other rods set in neutral position because of inter lock system.

NOTE: It is easy to remove the reverse rod if you use a handle of plastic hammer.





9. Loosen 5th & 6th shift check bolts and remove a spring, a rod, and a ball.
10. Remove a pin for 1st & 2nd fork.
11. Hold the fork rod, pull out the fork while hitting by a plastic hammer, and remove a fork from the housing.
12. Pull out the bracket's pin.
13. Cover some clothes because it's easy to fly over the pin.
14. Remove C-ring which stops fork.
15. Remove a same C-ring in the lower side.
16. Pull out the fork rod.





17. If it is not easy to come off, pull out the interlock pin in the fork rod.
18. Remove output shaft, input shaft, reverse idler gear and differential gear.





19. Pull out all check balls which remains in the housing.





20. Take off differential side bearing outer race and adjusting shim using special tool (09431-2C200).

REASSEMBLY





1. Press on the differential oil seal using special tool (09431 -2COOO).





2. Press on the input oil seal using special tool (094312C100).





3. Install the differential side bearing outer race using special tool (09431-2C300)





4. Install the oil channel.
5. Install the output shaft front bearing and output shaft retainer.





6. Fix a bolt.





7. Assemble the output shaft assembly, input shaft assembly, and reverse idler gear assembly to housing.
8. Assemble the magnet to housing.





9. Assemble 1 et-2nd bracket to a fork rod.
10. Insert 1 et-2nd fork rod to a fork.





11. Assemble 1st-2nd fork&fork rod to 1st-2nd coupling and rod hole.





12. Set a hole position of 1st-2nd fork and 1st-2nd fork rod.





13. Assemble the pins.
14. Insert the inter lock pin to the fork rod.





15. Insert a 3rd-4th fork rod to a 3rd-4th fork and 3rd-4th bracket.





16. Assemble 3rd-4th fork & fork rod to 3rd-4th coupling and rod hole.
17. Fix 3rd-4th fork by C ring





18. Set a hole position of 3rd-4th fork rod and 3rd-4th bracket.





19. Pins are put in a hole on the same way to 1 et-2nd fork rod.





20. Install 2 interlock balls with the magnet tool.





21. Install 5th-6th shift fork to 5th-6th coupling assembly.
22. Install the interlock pin to 5th-6th shift rod.

NOTE: Apply grease before putting inter lock pin. It's for falling off prevention.





23. Install 5th-6th fork rod to 5th-6th shift fork, and install 5th-6th fork rod to 3rd-6th shift fork hole. And the next, install 5th-6th bracket.

NOTE: Insert the fork rod which groove's direction keep 5th-6th check parts side.

24. Set the hole position of 5th-6th fork rod and 5th-6th shift fork.





25. Pin is put in hole on the same way to 1 et-2nd fork rod.





26. Fix 5th-6th bracket by 2 C-rings.
27. Install 2 inter lock balls with magnet tool.








28. Install the shift check ball, the shift check sleeve and the 5th-6th shift check spring, and then fix them by shift check plug.
29. Install the reverse bracket rod and the reverse bracket and put in order the reverse bracket direction.
30. Install the reverse shift fork to the reverse coupling assembly.





31. Install the shifter cap in the reverse shift fork and set them.
32. Install the reverse fork rod to reverse lever assembly.
33. Install the clutch housing while installing the reverse fork rod to the reverse shift fork.





34. Deside the knock pin's direction while pushing the reverse lever assembly, and put in it.
35. Fix 2 bolts.
36. Install the shift check ball, the reverse shift check sleeve and the reverse check spring, and then fix them by shift check plug.








37. Confirm the action of interlock system.





38. Install the input gear oil channel and the input gear bearing adjusting shim on input gear rear bearing.

NOTE: It is easy to fall down the shim, so apply grease on the shim.





39. Select the correct input gear adjusting shim of the input gear assembly to minimize the end play, and then put it.
End play (mm): 0 - 0.06
Shim thickness = L2 - L1 + end play








INPUT SHAFT BEARING ADJUSTING SHIM

40. Select correct output shaft bearing adjusting shim of output shaft assembly to minimize end play, and then put it.
End play (mm): 0 - 0.06
Shim thickness = A - B
41. Set a suitable jig at snap ring groove, then tighten bolt, and put end-face on the groove of snap ring.





42. Measure the dimension A1 and A2 from the mating face of transaxle case.

NOTE: For keeping accuracy, measure at least 3places and the calculated the average value.

A dimension = A2 - A1
43. Mounting to jig with the condition that snap ring is installed to output shaft rear bearing, and press it from upper side to eliminate the excessive play.
44. Measure the dimension from the upper face of output shaft rear bearing to upper face of jig without excessive play.








OUTPUT SHAFT BEARING ADJUSTING SHIM