Disassembly

Transaxle Case





1. Remove reverse switch, PNP switch, drain plug, and filler plug from transaxle case.





2. Remove snap rings from reverse idler shaft.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.





5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end.
b. Pull out the attached bolt, and remove reverse idler gear shaft from case.
6. Remove reverse idler gear, thrust washer (front, rear), and bearing from case.





7. Remove snap ring of mainshaft bearing from case.





8. Remove check plugs, springs, and check balls from case.





9. Remove mounting bolts.
10. Remove input shaft rear bearing adjusting shim from transaxle case.





11. Remove oil gutter from case.





12. Remove differential side bearing outer race and adjusting shim from case.





13. Remove differential oil seal from case.





14. Remove welch plugs from case.

Clutch Housing





1. Remove transaxle case from clutch housing.
2. Remove magnet from housing.
3. Remove check plugs, check springs, check pins, and check balls from housing.





4. Remove 3rd & 4th bracket retaining pin.





5. Remove 3rd & 4th shift fork stopper ring.
6. Remove 3rd & 4th fork rod.
7. Remove 3rd & 4th shift fork and bracket.





8. Remove interlock plunger and check ball.
9. Remove 5th & reverse bracket stopper ring.





10. Remove retaining pin from 5th & reverse shift fork and reverse switch bracket.
11. Remove 5th & reverse fork rod.
12. Remove interlock pin from 5th & reverse fork rod.
13. Remove reverse switch bracket and 5th & reverse bracket.





14. Remove check ball from housing.
15. Remove retaining pin for 1st & 2nd shift fork and bracket.
16. Remove 1st & 2nd fork rod.
17. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.





18. Remove both input shaft and mainshaft assemblies from housing.





19. Remove final drive assembly from housing.
20. Remove oil pocket from housing.





21. Remove mainshaft bearing retainer from housing.
22. Cut off oil channel using a cutter as shown in the figure.





23. Remove mainshaft front bearing from housing.





24. Using a magnet or other suitable tool, remove retaining pin from selector shaft.





25. Remove selector shaft and plug, then remove selector.





26. Remove reamer bolt, then remove select check leaf spring, return spring, steel ball, reverse gate, selector arm, bearing, and bushing.

CAUTION: Be careful not to lose the steel ball.





27. Remove retaining pin and plug from striking lever.





28. Remove striking rod, then striking lever from housing.
29. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing.

CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.





30. Remove differential oil seal from housing.





31. Remove differential side outer race from housing.