5TH/Reverse Gear and Housing Parts
Disassembly
Caution:
^ Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly.
^ Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
^ Clean out all holes end passages with compressed air and verify that there are no obstructions.
WARNING: USING COMPRESSED AIR CAN CAUSE DIRT AND OTHER PARTICLES TO FLY OUT, CAUSING INJURY TO EYES. WEAR PROTECTIVE EYE WEAR WHENEVER USING COMPRESSED AIR.
1. Mount the transaxle on the SST (OK130 990 007/OK130 175 011A).
2. Remove the release bearing and the release fork.
3. Remove the oil level gauge.
4. Remove the speed sensor.
5. Remove the backup lamp switch.
6. Remove the rear cover.
Notice: To remove the rear cover, lightly tap the rear cover using a plastic hammer.
Caution: Do not reuse the removed lock nut.
7. Lock the primary shaft with the SST(OK201 323 021).
8. Shift to 1st or 2nd gear to lock the rotation of primary shaft.
9. Uncrimp the tabs of the locknuts.
10. Remove the lock nut from the primary and secondary shaft and remove the reverse clutch cone and the reverse synchronizer sleeve from the primary shaft.
Caution: Do not reuse the removed roll pin.
11. Remove the roll pin from the 5th shift fork with a pin punch.
12. Remove the synchronizer ring and 5th shift fork, the 5th clutch hub assembly, 5th gear synchronizer ring, 5th gear sleeve at the same time.
13. Remove the secondary 5th gear.
14. After loosening the detent plug, remove the spring and the steel ball by using a magnetic stick.
15. Remove the reverse idle shaft lock bolt from the transaxle case assembly.
16. Remove the transaxle assembly.
Notice: To remove the transaxle case, lightly tap the transaxle case using a plastic hammer.
17. Remove the magnet.
18. Remove the reverse idle shaft and the reverse idle gear.
19. Remove the control case assembly after loosening 3 bolts.
20. Remove the lever spring set.
21. After putting shift lever in neutral, remove the roll pin from the 1/2 shift fork using a pin punch.
Notice: Do not reuse the removed roll pin.
22. Remove the 1/2 shift rod and the 1/2 shift fork.
23. After removing the roll pin from the 3/4 shift fork and the 3/4 shift rod end by using a pin punch, remove the 3/4 shift fork and shift rod end.
24. Remove E-Ring from the 5/R shift rod.
25. After removing the roll pin from the 5/R shift rod end by using a pin punch, remove the 5/R shift rod and 5/R shift rod end.
26. Remove the primary shaft geartrain and secondary shaft geartrain as an assembly.
27. Remove the differential assembly.
Assembly
Caution: Apply the transaxle oil to the differential bearing outer race.
1. Install the differential assembly in the clutch housing.
Caution:
^ Be sure not to damage the oil seal of the clutch housing side during installing the primary shaft.
^ Apply the transaxle oil to the lips of the primary oil seal.
^ Apply the transaxle oil to the secondary bearing outer race.
2. Install the primary shaft and the secondary shaft assembly in the clutch housing.
3. Assemble the 3rd/4th shift fork to the 3rd/4th clutch hub sleeve, insert the 5th/Rev shift rod into the shift fork and insert the 5th/Rev shift rod pin.
Notice: Use a new roll pin.
4. Align the 5th/Rev shift rod end with the 5th/Rev shift rod and insert the roll pin.
5. After inserting the 3rd/4th shift rod into the 3rd/4th shift fork, insert the 3rd/4th shift fork into the 3rd/4th shift rod end.
Notice: Use a new roll pin.
6. Align the 3rd/4th shift rod end with the 3rd/4th shift rod and insert the roll pin.
7. Align the 3rd/4th shift rod with 3rd/4th shift fork and insert the roll pin.
8. Assemble the 1 sV2nd shift fork to the 1st/2nd clutch hub sleeve, install the 1st/2nd shift rod.
Notice: Use a new roll pin.
9. Align the 1 stand shift rod with the 1st/2nd shift fork and insert the roll pin.
Notice: Use a new E-ring.
10. Insert the E-Ring into 5th/Rev shift rod.
11. Align the projection of the reverse shift lever with the 5th/Reverse shift rod end groove, and set the reverse shift lever to the clutch housing.
12. Install a new O-Ring to the reverse shift lever shaft.
Notice: Install the O-Ring so that it is on the outside.
13. Insert the reverse lever shaft into the reverse lever.
14. Insert the pin.
15. After assembling the lever spring set, tighten bolts.
Tightening torque: 5.8 - 8.3 ft. lbs. (7.8 - 11.3 Nm, 80 - 115 kg-cm)
16. After installing the control case assembly, tighten bolts.
Tightening torque: 5.8 - 8.3 ft. lbs. (7.8 - 11.3 Nm, 80 - 115 kg-cm)
Caution: When assembling the control case assembly make sure to use the correct length bolt.
Bolt (A) is longer than bolt (B).
17. Install the reverse idle shaft and the reverse idle gear.
18. Install the magnet.
Notice: Thoroughly clean sealants from clutch housing and the transaxle case.
19. Apply a thin coat of sealant (Threebond # 1216T or 1216TB) on the contacting surface of the clutch housing and the transaxle case.
20. Tighten the transaxle case mounting bolts.
Tightening torque: 13.7 - 18.8 ft. lbs. (18.6 - 25.5 Nm, 1.9 - 2.6 kg-m)
21. Tighten the reverse idle shaft locking bolt to the transaxle case assembly.
Tightening torque: 13.7 - 18.8 ft. lbs. (18.6 - 25.5 Nm, 1.9 - 2.6 kg-m)
Notice:
^ Since the length of detent springs are different, be sure to select the correct spring.
^ The length of detent spring: 5th/Rev is longer than 1st/2nd, 3rd/4th.
* Apply sealant to the detent plug.
22. Insert the steel ball, spring and tighten the detent plug.
Tightening torque: 10.8 - 15 ft. lbs. (15 - 20 Nm, 1.5 - 2.1 kg-m)
23. Assemble the secondary 5th gear.
Notice:
a) Since the shape of synchronizer ring are different, be sure to install correctly
b) There is missing synchronizer teeth in 3 places on the synchronizer ring of the reverse clutch hub assembly side.
Notice: Pay attention for the assembling direction of 5th gear sleeve.
24. Install the 5th gear sleeve, 5th gear and the synchronizer ring.
Caution: Assemble the oil groove of 5th clutch hub assembly to the 5th gear side.
25. After installing the 5th shift fork to the 5th clutch hub assembly, assemble the 5th clutch hub assembly and the 5th shift fork.
26. Assemble the synchronizer ring.
27. Assemble the reverse clutch cone and the reverse synchro sleeve at first, install it to the primary shaft.
Caution: Use a new roll pin.
28. Insert the roll pin to the 5th shift fork.
29. To prevent the primary shaft from rotating, shift to 1st and 2nd gear.
30. Install SST (OK201 171 010) on the primary shaft.
CAUTION: Use a new lock nut.
31. To prevent the lock nut from loosening after tightening it on to the primary shaft and secondary shaft, use caulking.
Tightening torque: 94 - 151 ft. lbs. (127 - 206 Nm, 13 - 21 kg-m)
32. Measure thrust clearance of the 5th gear and the reverse clutch cone with a dial indicator.
Clearance
5th gear: 0.0027 - 0.015 inch (0.07 - 0.39 mm)
Reverse clutch cone: 0.004 - 0.01 inch (0.1 - 0.25 mm)
If not within the specification, reassemble the transaxle.
Notice: Thoroughly clean sealants from the transaxle case and the rear cover.
33. Apply a thin coat of sealant (Threebond #1216 or 1216TB) to the contacting surface of the transaxle case and the rear cover.
34. Install the rear cover, making sure to align the stopper groove position of the reverse clutch cone. Tighten bolts.
Tightening torque: 5.8 - 8.3 ft. lbs. (7.8 - 11.3 Nm, 80 - 115 kg-cm)
35. Insert a washer onto the backup lamp switch and install the switch.
Tightening torque: 14 - 21.7 ft. lbs. (20 - 29.4 Nm, 2.0 - 3.0 kg-m)
36. Assemble the speed sensor to the speedometer driven gear.
Tightening torque: 5.8 - 8.3 ft. lbs. (7.8 - 11.3 Nm, 80 - 115 kg-cm)
37. Insert a bush to the change rod.
38. Assemble the release bearing and the release fork.
39. Remove the transaxle from the SST (OK 130 175 011A).
Caution: Do not damage the transaxle case.
40. Remove the secondary bearing outer race of the transaxle case with a screw driver.