5TH/Reverse Gear and Housing Parts Removal

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Part 2 Of 2:

5TH/REVERSE GEAR AND HOUSING PARTS

1. Measure the thrust clearance between 5th gear and the transaxle case.
2. Disassemble in the order shown, refering to the Disassembly Notes.





5TH GEAR THRUST CLEARANCE
1. Measure the primary reverse synchronizer and 5th gear thrust clearance using a dial indicator.

Clearance: 0.0032 - 0.0078 inch (0.080 - 0.200 mm)
Maximum: 0.0098 inch (0.250 mm)

2. If the clearance exceeds the maximum, check the contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY NOTES

Locknut





2. Mount the transaxle on the Special Service Tool (SST) (or equivalent).





3. Lock the primary shaft with the SST (or equivalent).
4. Shift to 1st or 2nd gear to lock the rotation of the primary shaft.

NOTICE: Do not reuse the removed locknut.

5. Uncrimp the tabs of the locknuts.
6. Remove the locknuts from the primary and secondary shafts.

Shift Fork And Shift Rod Assembly





1. Align the ends of the interlock sleeve and the control lever (arrow). Turn the shift rod counterclockwise.
2. While holding the 1st-2nd shift fork with one hand and the 3rd-4th shift fork with the other, raise them both at the same time and shift each of the clutch hub sleeves.





3. Lift the control end and remove the steel ball. At the same time, remove the shift rod from the clutch housing.
4. Separate the shift rod and shift fork assembly from each of the clutch hub sleeves.